Remove/install transmission

AR26.10-P-0020CW

13.12.11

TRANSMISSION 716.6 in MODEL 204, 207

P26.10-2150-09

Shown on model 204

1 Transmission

2 Diesel particulate filter unit bracket

3 Exhaust bracket

20 Propeller shaft

20V Flex disk

S16/2 Backup lamp switch

4 Rear engine crossmember

5 Rear engine mount

6 Line connection

7 Central clutch release bearing

Modification notes

25.6.10

Value modified: Self-locking nut, flexible coupling to transmission and front propeller shaft, M12

*BA41.10-P-1001-01I

 	Remove/install
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Open engine hood
		Model 207	AR88.40-P-1000EW
2	Detach ground line from battery	Model 204	AR54.10-P-0003CW
		Model 207	AR54.10-P-0003EW
	Notes on battery		AH54.10-P-0001-01A
3	Secure vehicle on vehicle lift		AR00.60-P-0100CW
4.1	Remove center and rear section of lower engine compartment paneling	Vehicles with gasoline engine
		Model 207	AR61.20-P-1105EW
4.2	Remove bottom sections of soundproofing	Model 204 with diesel engine
5	Remove catalytic converter bracket or diesel particulate filter unit bracket (2)	Engine 271, 646.8
		 Model 204 with engine 271	*BA49.10-P-1001-01AC
		 Model 207 with engine 271	*BA49.10-P-1010-01AE
		 Model 207 with engine 271	*BA49.10-P-1023-01AE
		 Engine 646	*BA49.10-P-1027-01AC
6	Detach exhaust bracket (3) on transmission (1) and exhaust pipe	 Model 204	*BA49.10-P-1008-01AC
		 Model 204	*BA49.10-P-1009-01AC
		 Model 207	*BA49.10-P-1023-01AE
		 Model 207	*BA49.10-P-1024-01AE
7	Detach exhaust pipe from catalytic converter	 Model 207	*BA49.10-P-1021-01AE
8	Detach ground line on transmission (1)	 Engines 271, 272	*BA15.10-P-1002-05C
9	Disconnect electrical connector to backup lamp switch (S16/2)
 Danger!	Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.	Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.	AS42.50-Z-0001-01A
10	Disconnect connector (6) for clutch actuation	 Seal connections immediately.
			*BA25.20-P-1002-01B
		 Set of stop plugs	*129589009100
11	Support transmission (1) and secure to prevent it from falling down
12	Remove rear engine crossmember (4) together with rear engine mount (5)		AR22.10-P-1180CW
	Notes on bolted connections with self tapping screws		AH00.00-P-0007-01SF
13	Mark propeller shaft (20)	 Apply color markings to the transmission (1) to indicate the position of the propeller shaft relative to the output flange. This ensures that the components are reinstalled at the factory installation position.
14.1	Detach flexible coupling (20V) from propeller shaft (20) and transmission (1)	Model 204
		 Check the flexible coupling (20V) for wear and damage; replace if necessary.
	Drift for loosening fitting sleeves in flex disks.		WF58.50-P-4110-01A
		 Installation: Install new self-locking nuts.
			*BA41.10-P-1001-01I
14.2	Detach flexible coupling (20V) from transmission (1)	Model 207
		 Check the flexible coupling (20V) for wear and damage; replace if necessary.
	Drift for loosening fitting sleeves in flex disks.		WF58.50-P-4110-01A
		 Installation: Install new self-locking nuts.
			*BA41.10-P-1001-01I
15	Detach center shifter console and shift rod from transmission (1)	 Installation: Lightly grease ball joint and safety bolt.	AR26.60-P-0600-02CW
		Long-life grease	*BR00.45-Z-1001-06A
16	Support engine	 The engine must be supported when removing the transmission (1) in order to prevent the engine from tilting, otherwise damage to the pilot bearing in the flywheel will occur.
17	Disconnect electrical connectors of heated oxygen sensors and unclip from retaining clips on transmission (1)	Model 204.05/ 25	AR07.52-P-5303CV
		Model 204.08	AR07.52-P-5303CWX
18	Remove bolts and remove transmission (1) diagonally downwards	 Installation: In order to avoid damage to the pilot bearing, carefully insert transmission (1) with input shaft into pilot bearing without tilting.
			*BA26.10-P-1001-01C
		 Installation on model 207: Attach the holder for the electrical lines to the heated oxygen sensors and the holders for the electrical wiring harness to the starter, to the transmission (1).
	Checking
19	Check central clutch operator (7)	If damage present:
		Replace central clutch operator (7).	AR26.40-P-0345CW
20	Remove clutch	Model 204	AR25.10-P-0050CW
		Model 207	AR25.10-P-0050CWA
21	Check clutch (pressure plate, clutch plate) for wear and damage	In the event of a complaint, replace clutch	AR25.10-P-0050-01CW
22	Check pilot bearing in flywheel for wear and damage	If damage present:
		Replace flywheel:
		Engine 271	AR03.30-P-8001CW
		Engine 272	AR03.30-P-8001CV
		Engine 646.8	AR03.30-P-8001T
		Engine 651 in model 204	AR03.30-P-8001CD
23	Check rear crankshaft radial sealing ring for leaks	If damage present:
		Replace crankshaft radial sealing ring:
		Engine 271	AR03.20-P-3063CW
		Engine 272	AR03.20-P-3063CV
		Engine 646.8	AR03.20-P-3063TXX
		Engine 651 in model 204	AR03.20-P-3063CD
24	Check dowel pins in transmission housing	If there is a complaint, replace dowel pins.
	Clean
25	Clean transmission input shaft on spline shaft toothing and guide	Cleaner from package	*BR00.45-Z-1028-04A
26	Grease transmission input shaft on spline shaft toothing all-round lightly with paste	 Make sure that no grease gets on the clutch lining or the central clutch release bearing (7), otherwise the boot of the central clutch release bearing (7) can be irreparably damaged.
		Paste	*BR00.45-Z-1005-06A
27	Install in the reverse order
28	Inspect transmission oil level	 Carry out oil level measurement with slanted hexagon socket wrench. Correct oil level = 10 mm below the bottom edge of the filler opening.
			*BA26.40-P-1003-01C
			*BF26.10-P-1001-01C
29	Bleed clutch operating system	Model 204	AR25.20-P-0070CW
		Model 207	AR25.20-P-0070CWA
 Danger!	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
30	Carry out an engine test run and check transmission (1) for leaks

 Exhaust system

Number	Designation		Engine 156, 271, 272 in model 204	Engine 642, 646, 651 in model 204


BA49.10-P-1001-01AC	Bolt, catalytic converter holder to catalytic converter	Nm	35	-
BA49.10-P-1008-01AC	Bolt, exhaust pipe bracket to transmission	Nm	20	20
BA49.10-P-1009-01AC	Bolt, exhaust pipe bracket to exhaust pipe	Nm	20	20
BA49.10-P-1027-01AC	Bolt/nut, bracket of diesel particulate filter to lower diesel particulate filter	Nm	-	20

 Ground strap

Number	Designation			Model 204	Model 207


BA15.10-P-1002-05C	Bolt, ground strap to transmission	M8	Nm	27	16
		M10	Nm	-	-

 Exhaust system

Number	Designation		Engine 271, 272, 273, 276, 278 in model 207


BA49.10-P-1010-01AE	Bolt, catalytic converter holder to catalytic converter	Nm	35
BA49.10-P-1021-01AE	Bolt, catalytic converter connecting pipe to catalytic converter	Nm	20
BA49.10-P-1023-01AE	Bolt of exhaust bracket to transmission	Nm	20
BA49.10-P-1024-01AE	Bolt/nut, exhaust bracket to exhaust	Nm	20

 Propeller shaft

Number	Designation			Model 204	Model 207


BA41.10-P-1001-01I	Self-locking nut, flex disk to transmission or front propeller shaft	M12	Nm	68	68

 Clutch operating mechanism

Number	Designation		Model 163, 170, 171, 202, 203, 204, 207, 208, 209, 210, 212, 230 with trans-mission 716.6


BA25.20-P-1002-01B	Union nut for clutch operating system line on hose	Nm	16

 Complete manual transmission

Number	Designation		Trans-mission 716.6


BA26.10-P-1001-01C	Bolt, transmission to engine	Nm	40

 Housing

Number	Designation		Trans-mission 716.6


BA26.40-P-1003-01C	Oil filler plug	Nm	35

 Transmission complete

Number	Designation			Transmission 716.60/61/62/ 630/631/632/ 633/634/635/ 636/638	Transmission 716.640/641/644/646/649, 716.653/654/655/656/657/658/66/67


BF26.10-P-1001-01C	Gear oil	Filling capacity	Liters	1.2	1.5
		Specifications for Operating Fluids	Sheet	BB00.40-P-0235-10A	BB00.40-P-0235-10A

Set of stop plugs

129 589 00 91 00

Repair materials

Number	Designation	Order number
BR00.45-Z-1028-04A	Cleaner from package	Adolf Würth GmbH & Co. KG Reinhold-Würth-Str. 12-17 74653 Künzelsau-Gaisbach Germany Tel. +49 7940 15-0 Fax +49 7940 15-1000 www.wuerth.de
BR00.45-Z-1001-06A	Long-life grease	A 000 989 63 51 11
BR00.45-Z-1005-06A	Paste, hot lubrication 1 kg, DB supply specification 6879.20	A 000 989 76 51

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