Remove/install transmission

AR26.10-T-0020B

Remove/install transmission

15.2.12

 

Remove/install

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant.

Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.

Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 Danger!

Risk of injury caused by touching hot retarder and by scalding from hot retarder oil. Risk of injury to skin or eyes caused by retarder oil escaping under high pressure

Do not carry out any work unless retarder is switched off. Wear suitable protective clothing and safety glasses when working on the hot retarder.

AS43.30-Z-0001-01A

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnect ground lead from battery



Notes on battery

All models

AH54.10-P-0001-01A

2

Remove floor panel above transmission (15) from inside of vehicle

3

Raise vehicle

AR00.60-T-1000B

4

Detach lower engine compartment paneling

AR61.20-T-1105B

5

Remove cross strut underneath transmission (15) from underbody



*BA61.10-N-1002-01A



*000589642100

6

Drain coolant



Drain/fill in coolant

AP20.00-T-2080-01B



Notes on coolant

All engines

AH20.00-N-2080-01A

7

Drain transmission oil

 Only when disassembling or replacing the transmission (15).



Manual transmission - oil change

AP26.00-T-2601A

8

Drain retarder oil

Only on Voith retarder R115 (integral), code B10



Retarder - oil change

With Voith retarder R115 (integral), code B10

AP43.30-T-4301A

9

Remove propeller shaft (7)

AR41.10-T-0050B

10

Remove clutch servo unit (17)

 Do not detach the lines.

AR25.20-T-0300B

11

Detach shift rod from transmission

Only on "Manual" gearshift, code G62

 Remove intermediate disk.



*BA26.60-N-1004-01E



*000589642100

12

Detach compressed air lines from shift cylinders on transmission (15)

Only on electronic power shift (EPS), code G61

13

Unplug connectors from sensors on shift cylinders on transmission (15)

Only on electronic power shift (EPS), code G61

14

Detach connecting hose (3) from connection fitting on oil/water heat exchanger (13)

Only on Voith retarder R115 (integral), code B10

15

Release fastening clamps on both water pipes on retarder (16)

Only on Voith retarder R115 (integral), code B10

16

Unplug coolant temperature sensor connector (9)

Only on Voith retarder R115 (integral), code B10

17

Unplug retarder oil temperature sensor connector (10)

Only on Voith retarder R115 (integral), code B10

18

Disconnect reservoir compressed-air line (12) from proportioning valve

Only on Voith retarder R115 (integral), code B10

 Discharge compressed air system beforehand.

19

Unplug proportioning valve connector (11)

Only on Voith retarder R115 (integral), code B10

20

Unplug backup lamp switch connector (1)

21

Unplug speedometer sensor connector (4)

22

Unplug starter lockout switch connector (8)

23

Support transmission (15) from below and secure

Engine support device, engine hoist
gotis://A_01_09.0

24

Support engine underneath and secure

Engine support device, engine hoist
gotis://A_01_09.0

25

Unscrew engine support arm from right and left engine mount



*BA22.10-N-1006-01E



*000589392100

26

Detach engine mount bearing bracket from right and left longitudinal member



*BA22.10-N-1001-01E



*000589642100

27

Remove bolts (2)

 First remove the top screws, then the bottom screws (2).

 Installation:

Do not tilt transmission (15) with clutch housing (14) when installing.



*BA25.10-N-1001-01H



*000589642100

28

Remove transmission (15) with clutch housing (14) out to the rear

 Slightly lift transmission (15) when removing and ensure there is sufficient clearance.

 Installation:

Clean the transmission input shaft and grease lightly with MB long-life grease. The clutch release bearing can be engaged by hand in the load ring through the clutch housing opening (14) using the clutch release fork with the clutch booster (17) removed.

Long-life grease

*BR00.45-Z-1001-06A

29

Install in the reverse order

30

Add transmission fluid

 Only when transmission (15) has been disassembled or replaced.



Manual transmission - oil change

AP26.00-T-2601A

31

Fill with retarder oil

Only on Voith retarder R115 (integral), code B10



Retarder - oil change

With Voith retarder R115 (integral), code B10

AP43.30-T-4301A

32

Pour in coolant



Drain/fill in coolant

AP20.00-T-2080-01B



Notes on coolant

All engines

AH20.00-N-2080-01A

*BF20.00-N-1001-01D

Number

Designation

Engine 402.970/
446.938
in model
613.455/
485

Engine
441.980 in model
613.355

BA22.10-N-1001-01E

Bolt, engine mount supporting bracket to side member

M12x1.5

Nm

70

70

BA22.10-N-1006-01E

Bolt, engine support arm to engine mount

Nm

195

195

Number

Designation

Engine 402.970

Engine 441.980

Engine 446.938

BA25.10-N-1001-01H

Bolt, clutch housing to engine housing

Nm

43

43

43

Number

Designation

Trans-mission 714.668

Trans-mission 714.690

BA26.60-N-1004-01E

Bolt, shift rod to transmission

Nm

24

24

Number

Designation

Model 613.355

Model 613.455

Model 613.485

BA61.10-N-1002-01A

Bolt, cross strut to side member

Nm

60

60

60

Number

Designation

Engines 402.970, 441.980, 446.938, 457.944

BF20.00-N-1001-01D

Filling capacity for coolant

without VOITH retarder

Liters

75 to 100

with VOITH retarder

Liters

95 to 120

Specifications for Operating Fluids

Sheet

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-02A

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11