Remove/install transmission

AR26.10-T-0020C

Remove/install transmission

15.2.12

31.10.00

Value changed from 60 Nm to 115 Nm

Value in BA61.10-N-1002-01A
changed for model 613.365

*BA61.10-N-1002-01A

 

Remove/install

 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

Disconnecting the battery

 First disconnect the negative terminal.

 To do this, unlock and pull out the battery tray.

2

Remove coolant lines

AR20.20-T-7440C

3

Remove floor plate above transmission

 The floor panel is located in the passenger footwell.

4

Detach cross strut below transmission from underbody



*BA61.10-N-1002-01A

5

Drain transmission oil



Manual transmission - oil change

AP26.00-T-2601B

 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

6

Drain retarder oil



Retarder - oil change

AP43.30-T-4301B

7

Remove propeller shaft

AR41.10-T-0050B

8

Remove clutch servo unit (17)

 Do not remove connected lines and bind up the clutch booster on substructure.

AR25.20-T-0300B

9

Detach shift rod from transmission

 Remove the intermediate disk



*BA26.60-N-1004-01E

10

Unplug water temperature sensor connector (9)

11

Unplug oil temperature sensor connector (10)

12

Detach supply air compressed air line (12) from proportioning valve

 Depressurize the system beforehand.

13

Unplug proportioning valve connector (11)

14

Unplug backup lamp switch connector (1)

15

Unplug speedometer connector (4)

16

Unplug starter lockout switch connector (8)

17

Support transmission (15) from below and secure

 Use a suitable unit jack or inspection pit lift.

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

18

Support engine underneath and secure

 Use a suitable unit jack or inspection pit lift.

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

19

Unscrew engine support arm from the front engine mounts on the right and left



*BA22.10-N-1006-01E

20

Remove front engine mount on left and right of the engine mount support plates



*BA22.10-N-1014-01E

21

Remove hexagon bolts (2) from clutch housing (14) at engine housing

 First unscrew the top hexagon bolts, then the bottom ones.

 Installation:

The clutch housing flange must abut the engine flange, i.e. do not tilt the transmission with clutch housing when installing.



*BA25.10-N-1001-01H

22

Pull transmission (15) and clutch housing (14) out to the rear

 When removing, lift the transmission slightly and ensure sufficient clearance.

 Installation:

- Clean the transmission input shaft and grease lightly with MB long-life grease.

- When the clutch booster is removed, the clutch release bearing can be engaged in the load ring by hand using the clutch release fork through the clutch housing opening.

Long-life grease

*BR00.45-Z-1001-06A

23

Install in the reverse order

24

Add transmission fluid



Manual transmission - oil change

AP26.00-T-2601B

25

Fill with retarder oil



Retarder - oil change

AP43.30-T-4301B

Number

Designation

Engine 441.980
in model
613.364/
365

BA22.10-N-1006-01E

Bolt, engine support arm to engine mount

Nm

195

Number

Designation

Engine 441.980
in model
613.364/
365

BA22.10-N-1014-01E

Bolt, front engine mount to engine mount support plate

M10

Nm

50

M12

Nm

110

M20

Nm

330

Number

Designation

Engine 441.980

BA25.10-N-1001-01H

Bolt, clutch housing to engine housing

Nm

43

Number

Designation

Trans-mission 714.120

Trans-mission
714.692

BA26.60-N-1004-01E

Bolt, shift rod to transmission

Nm

24

24

Number

Designation

Model 613.364/
365

BA61.10-N-1002-01A

Bolt, cross strut to side member

Nm

115

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11