Remove/install transmission

AR26.10-T-0020CB

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 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 electric cables at battery

AR54.18-T-0002CB



Notes on battery

All models

AH54.10-P-0001-01A

2

Release reservoir air from compressed air system

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

3

Raise vehicle

AR00.60-T-1000B

4

Detach lower engine compartment paneling

AR61.20-T-1105CA

5

Drain coolant



Drain/fill in coolant

AP20.00-T-2080-01CB



Notes on coolant

All engines

AH20.00-N-2080-01A

6

Drain transmission oil

 Only when disassembling or replacing the transmission (6).



Manual transmission - oil change

AP26.00-T-2601CA

 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

7

Drain retarder oil

 Only if there is a Voith retarder R115 (integral) Code B10 present and the transmission (6) is being disassembled or replaced.



Retarder - oil change

AP43.30-T-4301CA

8

Remove propeller shaft

Without Voith retarder R115 (integral) code B10.

With Voith retarder R115 (integral) code B10.

AR41.10-T-0050CA

9

Remove retarder coolant pipes (1)

Only on Voith retarder R115 (integral) code B10.

 The retarder coolant pipes (1) only need to be removed as far as the connecting point on the clutch housing.

10

Detach connector (2) on water temperature sensor

11

Detach connector (3) on proportioning valve

Only on Voith retarder R115 (integral) code B10.

12

Remove compressed-air connector (4) at proportioning valve

Only on Voith retarder R115 (integral) code B10.

For compressed-air connector
"VOSS 230".

AR42.10-W-0900A

For compressed-air connector
"VOSS 232" (NG 8, NG 12) or "Schäfer SDF" (NG 6).

AR42.10-W-0900C

13

Remove clutch booster

 Only carry out the steps for detaching the clutch booster from transmission (6). Do not remove the hydraulic line and pneumatic line on the clutch booster. Tie clutch booster up to underbody.

AR25.20-T-0300CA

14

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 (6) is removed.

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



Remove/install clutch operator
 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

Olista Longtime 3 E P

*BR00.45-Z-1062-06A

15

Remove maintenance flap above transmission (6)

 The maintenance flap is in the center aisle of the passenger compartment.

16

Detach shift cables (5) from transmission (6)

 Mark installation position of the shift cables (5).

 Installation: Observe marking, do not interchange shift cables (5).

17

Detach brackets of pneumatic lines (7, 8) from transmission (6)

 Only when required, detach pneumatic lines (7, 8) from engine if necessary:



For compressed-air connector
"VOSS 230".

AR42.10-W-0900A

On "VOSS 232" (NG 8, NG 12) or "Schäfer SDF" (NG 6) compressed-air connector.

AR42.10-W-0900C

18

Detach electrical cables between transmission (6) and body

 Do this by detaching the plugs (9, 10, 11, 12) from the transmission (6) and routing with the associated electrical cables so they do not interfere with the removal of the transmission (6).

19

Remove lower bolts (13) of clutch housing

 Detach the bracket for the lower engine cable set at the clutch housing.

20

Support and secure transmission (6)

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

21

Support and secure engine

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

22

Remove left and right transmission support arms (14)

23

Remove upper bolts (13) from clutch housing

 Installation: The flange of the clutch housing must lie flush with the flange of the engine.

24

Pull transmission (6) with clutch housing away from engine and remove from below

 Slightly lift transmission (6) when removing and ensure freedom of movement.

 Installation: Clean and lightly grease transmission input shaft. Do not tilt transmission (6) with clutch housing when installing.

Olista Longtime 3 E P

*BR00.45-Z-1062-06A

25

Remove release mechanism

AR25.10-T-0050-03BA

26

Install in the reverse order

Number

Designation

Order number

BR00.45-Z-1062-06A

Lubricating grease, Olista Longtime, DB supply specification 6804.60

A 001 989 36 51 10