Remove/install transmission

AR26.10-P-0020SA

06.03.2020

Transmission

711.6 in model 204

1	Transmission
2	Clip
3	Rear bracket
4	Rear engine cross member
5	Rear engine mount
6	Line connection
8	Diesel particulate filter
9	Ground cable
20	Propeller shaft
20V	Flex disk
S16/2	Backup lamp switch

P26.10-2169-06

P26.10-2170-09

1	Transmission		10	Heat shield		12	Retaining clamps
7	Central clutch release bearing		11	Safety clip

 Caution	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
Topical note	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
 	Remove/install
1	Open hood
2	Detach ground line from battery		AR54.10-P-0003CW
3	Secure vehicle on vehicle lift		AR00.60-P-0100CW
4.1	Remove rear section of lower engine compartment lining	Transmission 711.6 in model 204.0/2 with engine 272 Transmission 711.6 in model 204.0/2/3 with engine 271 Transmission 711.6 in model 204.0/2/3 with engine 274
			AR61.20-P-1105EW
4.2	Remove rear bottom part of soundproofing	Transmission 711.6 in model 204.0/2 with engine 642 Transmission 711.6 in model 204.0/2/3 with engine 651
			AR94.30-P-5300EW
5	Remove rear cross strut	 Bolt, rear reinforcement brace to frame floor assembly	*BA61.10-P-1003-01H
6	Detach rear bracket (3) from transmission (1) and diesel particulate filter (8)	Model 204 with engine 642 with transmission 711.6 Model 204 with engine 651 with transmission 711.6	AR49.10-P-7100CWI
7	Detach rear bracket (3) from transmission (1) and exhaust pipe	Model 204 (except 204.9) with engine 274 with transmission 711.6	AR49.10-P-7100MR
		Model 204 with engine 271, 272 with transmission 711.6	AR49.10-P-7100CW
8	Detach front bracket for catalytic converter from transmission (1), detach clamp securing catalytic converter to exhaust pipe and disconnect exhaust system	Transmission 711.6 in model 204 with engine 271 Transmission 711.6 in model 204 with engine 272	AR49.10-P-7100CW
		Transmission 711.6 in model 204 (except 204.9) with engine 274	AR49.10-P-7100MR
9	Detach ground line (9) from transmission (1)	 Screw/bolt, ground strap to transmission	*BA15.10-P-1002-05C
10	Support transmission (1) using major assembly mount and support plate, and lash down securely
	000 588 11 62 00 Major assembly mount		WS01.00-P-0092B
	000 588 10 62 00 Support plate		WS26.00-P-3309B
11	Detach flex disk (20V) from propeller shaft (20) and transmission (1)		AR41.10-P-0050CW
12	Release and disconnect electrical connection from backup lamp switch (S16/2) and from neutral position switch
13	Detach center shifter console and shift rod from transmission (1)		AR26.60-P-0600-02CW
		 Installation: Lightly grease ball joint and safety bolt.
		Long-life grease	*BR00.45-Z-1001-06A
14	Undo securing clamp (11) using a suitable tool and detach heat shield (10) from transmission (1)	If installed.
15.1	Disconnect line connection (6) of clutch operating system and seal connections using suitable stop plugs	Vehicles with single-plate dry clutch
		 Union nut for clutch operating system line on hose	*BA25.20-P-1002-01B
		 Record plug	*129589009100
15.2	Detach clutch slave cylinder from transmission (1) and secure to underfloor	Vehicles with dual-plate dry clutch
		Transmission 711.6 in model 204Vehicles with double-plate clutch	AR25.20-P-0150CW
16	Remove bolts and remove transmission (1) diagonally downwards	 Installation: Insert the transmission input shaft into the pilot bearing carefully and without tilting. Otherwise the pilot bearing in the flywheel will be damaged.
		 Bolt, transmission to engine	*BA26.10-P-1001-01F
		 Bolt, starter position cover	*BA26.10-P-1002-01F
	Check
17	Check central clutch release bearing (7) for wear and damage		AR26.40-P-0345CW
		In event of wear or damage
		
		Replace central clutch operator (7)
18	Remove clutch and check for wear and damage		AR25.10-P-0050CW
		In event of wear or damage
		
		Replace clutch
19	Check pilot bearing in flywheel for wear and damage	Transmission 711.6 in model 204 with engine 271	AR03.30-P-8001CW
		Transmission 711.6 in model 204 with engine 272	AR03.30-P-8001CV
		Transmission 711.6 in model 204 with engine 274	AR03.30-P-8001MR
		Transmission 711.6 in model 204 with engine 642	AR03.30-P-8001CO
		Transmission 711.6 in model 204 with engine 651	AR03.30-P-8001CD
		In event of wear or damage
		
		Replace pilot bearing
20	Check rear radial shaft sealing ring for leaktightness	Transmission 711.6 in model 204 with engine 271	AR03.20-P-3063CW
		Transmission 711.6 in model 204 with engine 272	AR03.20-P-3063CV
		Transmission 711.6 in model 204 with engine 274	AR03.20-P-3063MR
		Transmission 711.6 in model 204 with engine 642	AR03.20-P-3063CO
		Transmission 711.6 in model 204 with engine 651	AR03.20-P-3063CD
		In event of wear or damage
		
		Replace rear radial shaft sealing ring
21	Check dowel pins in transmission housing for wear and damage	In event of wear or damage
		
		Replace dowel pins
	Clean
22	Clean transmission input shaft on splined shaft and guide	Assembly cleaner	*BR00.45-Z-1028-04A
23	Apply light coating of paste all way round the transmission input shaft on the splined shaft	 It must be ensured that no grease is allowed to touch the clutch lining and the central clutch release bearing (7). Otherwise the boot of the central clutch release bearing (7) will be irreparably damaged.
		Paste, hot lubrication 1 kg, DBL 6879.20	*BR00.45-Z-1005-06A
24	Install in the reverse order
25	Check transmission oil level and correct if necessary	 Oil filler screw to transmission housing (thread oiled)	*BA26.40-P-1005-01E
		 Gear oil	*BF26.10-P-1001-01G
26	Bleed clutch operating system	On vehicles with single-plate dry clutch.
			AR25.20-P-0070CW
 Warning	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
27	Test run engine and check transmission (1) for leak tightness and proper operation

 Ground strap

Number	Designation			Model 204
BA15.10-P-1002-05C	Screw/bolt, ground strap to transmission	M8	Nm	27
		M10	Nm	-

 Clutch operating system

Number	Designation		Transmission 711.6 (except 711.640/641)
BA25.20-P-1002-01B	Union nut for clutch operating system line on hose	Nm	16

 Manual transmission complete

Number	Designation		Transmission 711.65	Transmission 711.67
BA26.10-P-1001-01F	Bolt, transmission to engine	Nm	39	39

 Manual transmission complete

Number	Designation		Transmission 711.65	Transmission 711.67
BA26.10-P-1002-01F	Bolt, starter position cover	Nm	39	39

 Housing

Number	Designation		Transmission 711.64/65	Transmission 711.67
BA26.40-P-1005-01E	Oil filler screw to transmission housing (thread oiled)	Nm	35	33

 Frame floor assembly

Number	Designation		Model 204
BA61.10-P-1003-01H	Bolt, rear reinforcement brace to frame floor assembly	Nm	24

 Complete transmission

Number	Designation			Transmission 711.653/654	Transmission 711.655/656
BF26.10-P-1001-01G	Gear oil	Filling capacity	Liter	1,5	1,2
		Sheet		BB00.40-P-0235-10A	BB00.40-P-0235-10A

 Complete transmission

Number	Designation			Transmission 711.670
BF26.10-P-1001-01G	Gear oil	Filling capacity	Liter	1,8
		Sheet		BB00.40-P-0235-10A

129 589 00 91 00

Record plug

Repair materials

Number	Designation	Order number
BR00.45-Z-1001-06A	Long-life grease	A 000 989 63 51 11
BR00.45-Z-1005-06A	Paste, hot lubrication 1 kg, DBL 6879.20	A 000 989 76 51
BR00.45-Z-1028-04A	Assembly cleaner	A 000 986 56 01

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