Remove/install transmission

AR26.10-T-0020BA

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

AR54.18-T-0002BA



Notes on battery

All models

AH54.10-P-0001-01A

2

Release compressed air from compressed air system

 Actuate drain valve on reservoirs.

3

Raise vehicle

 Position over a pit if necessary.

AR00.60-T-1000B

4

Detach lower engine compartment paneling

AR61.20-T-1105B

5

Remove cross strut (1)

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 (8).



Manual transmission - oil change

AP26.00-T-2601BA

8

Drain retarder oil

Only on Voith retarder R115 (integral), code B10, and if the transmission (8) is disassembled or replaced.



Retarder - oil change

AP43.30-T-4301B

9

Remove propeller shaft

AR41.10-T-0050B

10

Remove retarder coolant pipes (2)

 The retarder coolant pipes (2) only need to be removed as far as the connecting point on the clutch housing.

11

Detach coolant temperature sensor electrical connector (3)

12

Detach proportioning valve compressed air line (4)

Only on Voith retarder R115 (integral), code B10, or on Voith retarder R120, code B11

13

Detach proportioning valve connector (5)

Only on Voith retarder R115 (integral), code B10, or on Voith retarder R120, code B11

"VOSS 230" compressed-air connector

AR42.10-W-0900A

Compressed-air connector "VOSS 232" (NG 8, NG 12) or "SCHÄFER SDF" (NG 6)

AR42.10-W-0900C

14

Remove clutch servo unit (6)

 Note the following:

 Do not detach the hydraulic line or pneumatic line from the clutch booster (6).

 Only perform steps for removing clutch booster (6) from transmission (8).

 Tie up clutch booster (6) to substructure.

AR25.20-T-0300BA

15

Remove plunger for operating release fork

 So that the clutch release fork can extend out of the groove of the clutch release bearing when the transmission (8) is removed.

 Installation: Latch clutch release bearing into the circlip of the pressure plate: 

Remove/install release mechanism

 Once the clutch release bearing has latched, audibly and perceptibly latch the plunger for operating the clutch release fork into the clutch release fork.

AR25.10-T-0050-03BA

*BR00.45-Z-1062-06A

16

Remove floor panel above transmission (8)

 The floor panel is in the center aisle of the passenger compartment.

17

Detach shift rod (8) from transmission

Only on transmission 714.120/140 with "Manual" gearshift, code G62

18

Detach shift cables from bracket and from relay lever

Only on transmission 714.120/140 with "Control cable" gearshift, code G63

 Do not alter settings of the shift cables.

19

Detach compressed-air lines from shift cylinders on transmission

Only on transmission 714.120/140 with electronic power shift (EPS), code G61

20

Unplug connectors from sensors for shift cylinders on transmission

Only on transmission 714.120/140 with electronic power shift (EPS), code G61

21

Detach shift rod (8) from transmission

22

Remove compressed-air resonance tank (7)

23

Detach constant throttle/engine brake compressed air line (9) and air compressor compressed air line (10)

"VOSS 230" compressed-air connector

AR42.10-W-0900A

Compressed-air connector "VOSS 232" (NG 8, NG 12) or "SCHÄFER SDF" (NG 6)

AR42.10-W-0900C

24

Detach retarder oil temperature sensor connector (11)

Only on Voith retarder R115 (integral), code B10, or on Voith retarder R120, code B11

25

Unplug backup lamp switch connector (12)

26

Unplug speedometer sensor connector (13)

27

Unplug starter lockout switch connector (14)

28.1

Adjust engine support bolts

 If support bolts are present on the engine.

AR22.20-T-0020-01BA

28.2

Support engine and secure with suitable equipment jack to prevent it falling down and toppling

 If support bolts are not present on the engine.

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

29

Support transmission (8) using lifting platform and secure with a suitable lashing strap to prevent it from falling or tipping over

Vehicle lift for major assemblies/scissors-type pallet forklift

gotis://A_01_07.1

Lashing straps as tilt control
gotis://H_00.1_05.2

30

Remove bolts (15) from top of clutch housing

31

Remove the supporting arms (16) on the left and right of the transmission (8)

32

Remove bolts (15) from bottom of clutch housing

 Installation: The clutch housing flange must touch flat against the engine flange, i.e. keep the transmission (8) and clutch housing straight when installing.

33

Pull transmission (8) backwards and lower

 Ensure that the transmission (8) has sufficient clearance.

 Installation: Clean and lightly grease transmission input shaft.

Remove any excess grease.

Install the clutch release bearing on the clutch release fork before installing the transmission (8): 

Remove/install release mechanism

AR25.10-T-0050-03BA

*BR00.45-Z-1062-06A

34

Install in the reverse order

35

Fill with transmission oil

 Only perform step if the transmission oil is being changed or the transmission has been disassembled.



Manual transmission - oil change

AP26.00-T-2601BA

Number

Designation

Order number

BR00.45-Z-1062-06A

Lubricating grease, Olista Longtime, DB supply specification 6804.60

A 001 989 36 51 10