Remove/install transmission

AR26.10-P-0020P

Remove/install transmission

20.03.2015

TRANSMISSION

711.65 in MODEL 203

TRANSMISSION

716.6 in MODEL 203, 209.3/4

without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

Shown on transmission 716.6 with selector cable

1

Transmission

8

Bracket

15

Nuts

2

Bolts

9

Nut

16

Bolt

3

Safety bolt

10

Spacer ring

17

Front propeller shaft

4

Connection piece

11

Hydraulic line

18

Cap

5

Shift rod

12

Engine support

19

Bolts

6

Connection for center-mounted shift mechanism / transmission

13

Exhaust bracket

20

Ground cable

7

Selector cable

14

Bolts

X49/1

Backup lamp switch connector

Shown on transmission 716.6 with selector cable

21

Bolts

22

Refrigerant line

 

Remove/install

 Danger !

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

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

AS00.00-Z-0010-01A

 Danger !

Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid

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

 Danger !

Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries

No fires, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers.

AS54.10-Z-0001-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Detach ground line from battery

MODEL 203

AR54.10-P-0003P



Notes on battery

AH54.10-P-0001-01A

MODEL 209

AR54.10-P-0003Q


Insulate ground line.
A short circuit can otherwise occur.

2

Remove air filter housing

Engine 111.951

AR09.10-P-1150PR

Engine 111.955/ 981

AR09.10-P-1150PK

Engine 112

AR09.10-P-1150SVK

Engine 271

AR09.10-P-1150Q

ENGINE 272

AR09.10-P-1150QB

Engine 611, 612

AR09.10-P-1050C

Engine 642

AR09.10-P-1150PI

ENGINE 646

AR09.10-P-1150PM

 Installation: Lightly grease the rubber guide for assembly.

Long-life grease

*BR00.45-Z-1001-06A

3.1

Remove lower engine compartment paneling

MODEL 203, 209 with gasoline engines

AR61.20-P-1105P

3.2

Remove bottom sections of soundproofing

MODEL 203, 209 with diesel engines

AR94.30-P-5300P

4.1

Remove rear exhaust system

MODEL 203, 209 except engine 271.942

ENGINE 111

AR49.10-P-7000PR

Engine 112

AR49.10-P-7000PV

Engine 271 except engine 271.942

AR49.10-P-7000QK

ENGINE 272

AR49.10-P-7000QB

Engine 611, 612

AR49.10-P-7000PP

Engine 642

AR49.10-P-7000PI

ENGINE 646

AR49.10-P-7000PM

4.2

Remove complete exhaust system

Engine 271.942

AR49.10-P-7000QD

5

Remove exhaust bracket (13)

 To do so, unscrew the bolts (14) and nuts (15).

6

Remove bolts (21) and place refrigerant line (22) to one side

MODEL 209.3/4 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

 Mark the installation position of the refrigerant line (22).

7

Detach front propeller shaft (17) from transmission (1)

AR41.10-P-0050-02EA

AR41.10-P-0050-07EA

 The flexible coupling remains on the front propeller shaft (17).

 Installation: Attach the front propeller shaft (17) to the transmission (1).

 TRANSMISSION 711.65 in MODEL 203
TRANSMISSION 716.6 in MODEL 203, 209.3/4
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

*BA41.10-P-1001-01A

 Torque wrench

*001589662100

8

Undo fitted sleeves of flexible coupling and slide back front propeller shaft (17)

AR41.10-P-0050-09DA



WF58.50-P-4110-01A

9

Disconnect backup light switch connector (X49/1)

10

Disconnect hydraulic line (11) of clutch operation

 Record plug

*129589009100



Brake fluid notes

AH42.50-P-0001-01A

11

Support and lash down transmission (1)

12

Remove engine support (12) with engine mount; to do so, remove bolts (16, 19) and detach ground line (20)

MODEL 203, 209 with engine 111, 112, 271, 646

AR22.10-P-1160PR

MODEL 203 with engine 611, 612 MODEL 209 with engine 612

AR22.10-P-1160HC

MODEL 203 with engine 272

AR22.10-P-1160QB

MODEL 203, 209 with engine 642

AR22.10-P-1160PI

 The engine mount remains on the engine support (12).

Perform operation steps 13 to 17 on transmission (1) with selector cable

13

Release safety bolt (3) and pull out

14

Detach shift rod (5) from ball head on transmission (1)

 Installation: Lightly grease ball joint.

Long-life grease

*BR00.45-Z-1001-06A

15

Detach cap (18) from bracket (8)

 Installation: First insert the upper guide of the cap (18) and then clip in at the bottom.

16

Detach selector cable (7) from bracket (8)

 Turn the nut (9) counterclockwise and remove the selector cable (7).

 Installation: Lightly grease the ball joint of the selector cable (7).

 Installation: Make sure that the spacer ring (10) is seated correctly on the selector cable (7).

Long-life grease

*BR00.45-Z-1001-06A

17

Secure selector cable (7) on inside of transmission tunnel

Perform operation step 18 on transmission (1) with single-rod gearshift

18

Detach shift rod (5) from transmission (1)

TRANSMISSION 716.6 in MODEL 203, 209 with ENGINE 642
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

AR26.60-P-0600-02PI

TRANSMISSION 711.65 in MODEL 203 TRANSMISSION 716.6 in MODEL 203, 209 except ENGINE 642 except CODE 424 (Sequentronic automated manual transmission (SEQ))

AR26.60-P-0600-02V

19

Detach pipe from engine oil pan

MODEL 203, 209 except engine 642

 ENGINE 111.951/955 in MODEL 203 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))
ENGINE 111.98 in MODEL 203 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))
ENGINE 611.962 in MODEL 203 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))
ENGINE 612.962 in MODEL 203 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))
ENGINE 612.962 in MODEL 209.3 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))
ENGINE 612.967 in MODEL 209.3 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

*BA01.45-P-1001-01A

 ENGINE 112.912 in MODEL 203 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))
ENGINE 112.912 in MODEL 209.3 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))
ENGINE 112.912 in MODEL 209.4 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))
ENGINE 112.946 in MODEL 203 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

*BA01.45-P-1001-01B

 ENGINE 271 in MODEL 203 with TRANSMISSION 711.65
ENGINE 271 in MODEL 203 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))
ENGINE 271 in MODEL 209.3 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))
ENGINE 271 in MODEL 209.4 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

*BA01.45-P-1001-01H

 ENGINE 272 in MODEL 203 with TRANSMISSION 711.65
ENGINE 272 in MODEL 203 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))
ENGINE 272 in MODEL 209.3 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))
ENGINE 272 in MODEL 209.4 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

*BA01.45-P-1002-01M

 ENGINE 646.962/963 in MODEL 203 with TRANSMISSION 711.65
ENGINE 646.966 in MODEL 209.3 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

*BA01.45-P-1001-01G

20

Remove screws/bolts (2)

 TRANSMISSION 711.65 in MODEL 203

*BA26.10-P-1001-01F

 ENGINE 111.951/955 in MODEL 203 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))
ENGINE 612.962 in MODEL 203 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))
ENGINE 612.962 in MODEL 209.3 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))
ENGINE 612.967 in MODEL 209.3 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

*BA01.45-P-1002-01A

 TRANSMISSION 716.6 in MODEL 203, 209.3/4
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

*BA26.10-P-1001-01C

 ENGINE 646.962/963 in MODEL 203 with TRANSMISSION 711.65
ENGINE 646.966 in MODEL 209.3 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

*BA01.45-P-1002-01G

 ENGINE 271 in MODEL 203 with TRANSMISSION 711.65
ENGINE 271 in MODEL 203, 209.3/4 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

*BA01.45-P-1006-01H

21

Turn lead pipe down out of the way

MODEL 203, 209 except engine 642

22

Remove transmission (1) downwards at an angle

 Installation:
Carefully insert the transmission (1) with transmission input shaft into the pilot bearing without tilting it.
The pilot bearing will otherwise be damaged.

23

Check thrust bearing and deep-groove ball bearing of crankshaft

24

Install in the reverse order

25

Check transmission oil level and correct if necessary



TRANSMISSION 716.6 as of 2/1/01 in MODEL 203, 209.3/4
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

BT26.00-P-0001-01A

 Measure with angled hexagon head spanner for example.

 TRANSMISSION 711.65 in MODEL 203

*BA26.40-P-1005-01E

 TRANSMISSION 711.653/654 in MODEL 203
TRANSMISSION 711.655/656 in MODEL 203

*BF26.10-P-1001-01G

 TRANSMISSION 716.60 in MODEL 203
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))
TRANSMISSION 716.62 in MODEL 203, 209.3/4
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))
TRANSMISSION 716.63 in MODEL 203, 209.3/4
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

*BF26.10-P-1001-01C

 TRANSMISSION 716.6 in MODEL 203, 209.3/4
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

*BA26.40-P-1003-01C

26

Bleed clutch operating system

AR25.20-P-0070P

27

Check shift mechanism for ease of movement

TRANSMISSION 711.65 in MODEL 203
TRANSMISSION 716.6 in MODEL 203, 209.3/4
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))



TRANSMISSION 716.6 as of 6/1/00 in MODEL 203
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

BT26.60-P-0008-02A

On vehicles with transmission (1) with selector cable (7) if shift mechanism is sluggish:



Adjust selector cable (7).

MODEL 203, 209 as of approx. 06/2000

AR26.60-P-0635-02E

MODEL 203 up to approx. 05/2000

AR26.60-P-0635-02D

 Adjustment gauge

*716589002300

28

Perform basic programming

MODEL 203 with TRANSMISSION 711.65
MODEL 203 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

AR00.19-P-0200P

MODEL 209 with TRANSMISSION 716.6
without CODE 424 (SEQUENTRONIC (easy-shift m.transmission))

AR00.19-P-0200Q

29

Connect STAR DIAGNOSIS, read out fault memory and erase if necessary



AD00.00-P-2000-04A

 Danger !

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

30

Perform engine test run and check transmission (1) for proper operation and leaktightness

 Oil pan

Number

Designation

ENGINE 111.951/955/958

ENGINE 111.92/94/952/956/957/96/97/98

BA01.45-P-1001-01A

Bolt, oil pan to cylinder crankcase

M6

Nm

8

10

M8

Nm

20

25

M10

Nm

–

–

 Oil pan

Number

Designation

ENGINE 611.960/961/962

ENGINE 612.961/962/963/965/966 ENGINE 613.961

BA01.45-P-1001-01A

Bolt, oil pan to cylinder crankcase

M6

Nm

9

9

M8

Nm

20

20

M10

Nm

–

–

 Oil pan

Number

Designation

ENGINE 612.967

BA01.45-P-1001-01A

Bolt, oil pan to cylinder crankcase

M6

Nm

9

M8

Nm

20

M10

Nm

–

 Oil pan

Number

Designation

Engine 112.910/ 911/912/913/914/ 915/917/920/921/ 922/923/940/941/ 942/943/944/945/ 946/947/949/951/ 954/955/960/961/ 970/972/973/976

BA01.45-P-1001-01B

Bolt, oil pan to cylinder crankcase

M6

Nm

9

M8

Nm

20

 Oil pan

Number

Designation

ENGINE 646.951/961/962/963/966

BA01.45-P-1001-01G

Bolt, oil pan to cylinder crankcase

M6

Nm

9

M8

Nm

20

M10

Nm

–

 Oil pan

Number

Designation

ENGINE 271

BA01.45-P-1001-01H

Bolt, oil pan to cylinder crankcase

M630

Nm

9

M690

Nm

9

M835

Nm

20

 Oil pan

Number

Designation

ENGINE 111.951/955/958

ENGINE 612.961/962/963/965/966 ENGINE 613.961

BA01.45-P-1002-01A

Bolt, transmission bell housing to oil pan

Nm

40

40

 Oil pan

Number

Designation

ENGINE 612.967

BA01.45-P-1002-01A

Bolt, transmission bell housing to oil pan

Nm

38

 Oil pan

Number

Designation

ENGINE 646.951/961/962/963/966

BA01.45-P-1002-01G

Bolt, transmission bell housing to oil pan

Nm

40

 Oil pan

Number

Designation

ENGINE 272

BA01.45-P-1002-01M

Screw/bolt, oil pan to cylinder crankcase, timing case cover or rear cover

Nm

9

 Oil pan

Number

Designation

ENGINE 271

BA01.45-P-1006-01H

Bolt, transmission bell housing to oil pan

Nm

38

 Manual transmission complete

Number

Designation

TRANSMISSION 716.6

BA26.10-P-1001-01C

Bolt, transmission to engine

Nm

40

 Manual transmission complete

Number

Designation

TRANSMISSION 711.65

BA26.10-P-1001-01F

Bolt, transmission to engine

Nm

39

 Housing

Number

Designation

TRANSMISSION 716.6

BA26.40-P-1003-01C

Oil filler screw

Nm

35

 Housing

Number

Designation

TRANSMISSION 711.64/65

BA26.40-P-1005-01E

Oil filler screw to transmission housing (thread oiled)

Nm

35

 Propeller shaft

Number

Designation

MODEL 203

MODEL 209

BA41.10-P-1001-01A

Self-locking nut, flexible coupling to transmission or front propeller shaft

M10

Nm

40

40

M12

Nm

60

60

 Complete transmission

Number

Designation

TRANSMISSION 716.60 in MODEL 203, 204, 207, 211, 212
TRANSMISSION 716.61 in MODEL 204, 207, 212
TRANSMISSION 716.62 in MODEL 203, 209, 211
TRANSMISSION 716.63 in MODEL 171, 203, 204, 209, 211, 212

BF26.10-P-1001-01C

Transmission oil

Filling capacity

Liter

1,2

Sheet

BB00.40-P-0235-10A

 Complete transmission

Number

Designation

TRANSMISSION 711.653/654

TRANSMISSION 711.655/656

BF26.10-P-1001-01G

Transmission oil

Filling capacity

Liter

1,5

1,2

Sheet

BB00.40-P-0235-10A

BB00.40-P-0235-10A

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11