Remove/install transmission

AR26.10-P-0020T

Remove/install transmission

19.11.09

20.6.08

Note on pilot bearing inserted

Step 23

 

Remove/install



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Disconnect battery ground cable

Model 211.0

AR54.10-P-0003T

Model 211.2

AR54.10-P-0003TA



Notes on battery

AH54.10-P-0001-01A

2.1

Remove rear part of bottom part of noise encapsulation

Vehicles with diesel engine

AR94.30-P-5300T

2.2

Remove rear part of engine compartment paneling

Vehicles with gasoline engine

AR61.20-P-1105T

3

Detach retaining bracket (1) of the rear bottom part of soundproofing

Vehicles with diesel engine

4

Detach ground line (2) from transmission (3)

5

Detach pipe (4) from transmission (3) and engine oil pan

Engines 646, 647



*BA01.45-P-1001-01G



*BA01.45-P-1002-01G

6

Disconnect electrical connector from backup lamp switch (S16/2)

7

Remove three way catalytic converter bracket (5)

 Check the rubber bushing (5a) for wear and replace if necessary.

 Engine 112: Remove the left and right catalytic converter bracket.

Engines 646, 647



*BA49.10-P-1001-01I



*BA49.10-P-1002-01I

Engine 112



*BA49.10-P-1012-01A



*BA49.10-P-1011-01A

Engine 271



*BA49.10-P-1004-01K



*BA49.10-P-1005-01K

Engine 272



*BA49.10-P-1005-01T



*BA49.10-P-1007-01T

8

Remove O2 sensor downstream of catalytic converter

Engine 112, 271, 272

 Engine 112: Remove the O2 sensor downstream of the catalytic converter on the right and left side.

AR14.00-P-5303T

Engine 271

AR07.52-P-5303TK

Engine 272

AR07.52-P-5303TS

9

Remove front catalytic converter bracket on transmission (3)

Engine 271, 272

Engine 271



*BA49.10-P-1010-01K



*BA49.10-P-1011-01K

Engine 272



*BA49.10-P-1006-01T

10

Detach center shifter console and shift rod from transmission (3)

Vehicles with single-rod gearshift

AR26.60-P-0600-02TS

Long-life grease

*BR00.45-Z-1001-06A

11

Remove flexible coupling (6)

 Check the flexible coupling (6) for wear and replace if necessary.

AR41.10-P-0050-02T



*BA41.10-P-1001-01A

 Installation: Attach the propeller shaft to the transmission (3).

AR41.10-P-0050-07I



*BA41.10-P-1001-01A

12

Loosen fitted sleeves in flexible couplings and pull propeller shaft off output flange

AR41.10-P-0050-09DA



Drift for loosening fitting sleeves in flex disks.

WF58.50-P-4110-01A

13

Press shift rod (8) vertically upward off ball head (9)

Vehicles with selector cable gearshift

 Use an open end wrench to pry off the shift rod (8).

 Installation: Lightly grease ball head (9).

Long-life grease

*BR00.45-Z-1001-06A

14

Remove safety bolt (7a) and remove floor shift (7) from transmission (3).

Vehicles with selector cable gearshift

15

Support and lash down transmission (3)

16

Remove rear engine cross member (10)

Engine 112, 271, 646, 647

AR22.10-P-1160T

Engine 272

AR22.10-P-1180TS

17

Remove cover (11).

 Installation: Insert upper guide of cover (11) at the top of the housing (12), then clip in cover (11) at the bottom of the housing (12). The retaining tabs must latch audibly.

18

Unhook selector cable (13) from relay lever (14)

Vehicles with selector cable gearshift

 Installation: Grease ball joint on relay lever (14) lightly.

Long-life grease

*BR00.45-Z-1001-06A

19

Turn nut (15) in the direction of the arrow and remove selector cable (13) from housing (12)

 Installation: Pay attention to correct seating of spacer ring (16). The spacer ring (16) only serves as an assembly aid and does not influence the function of the gearshift.

 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

20

Disconnect connector (17) for clutch actuation

 Seal connections immediately.



*129589009100



Brake fluid notes

AH42.50-P-0001-01A

21

Lower transmission (3) at output end

22

Support engine at the engine oil pan

 When taking out the transmission (3) the engine must not tilt at the splash wall otherwise the brake lines routed there will be damaged.

23

Remove the transmission bolts (18) and remove the transmission (3) downwards at an angle

 Installation: In order to avoid damage to the pilot bearing (19), carefully insert the transmission (3) with transmission input shaft into the pilot bearing (19) without tilting.



*BA26.10-P-1001-01C



Checking

24

Check pilot bearing (19) in the flywheel (20)

 If noisy or rough running and wear: 

Replace flywheel (20):

Engines 646, 647

AR03.30-P-8001T

Engine 112

AR03.30-P-8001C

Engine 271

AR03.30-P-8001TK

Engine 272

AR03.30-P-8001TS

25

Install in the reverse order

26

Check and correct the transmission oil level

 Correct oil level = 10 mm below bottom edge of filler opening.

 Carry out measurement e.g. with angled hexagon socket wrench.



*BA26.40-P-1003-01C



*BF26.10-P-1001-01C

27

Bleed clutch operating system

AR25.20-P-0070P

28

Check shift mechanism for ease of movement

Vehicles with selector cable gearshift

If necessary, adjust selector cable (13).

AR26.60-P-0635-02E



*716589002300

Number

Designation

Engine 646.951/
961/962/
963/966

Engine
646.8

Engine
647

BA01.45-P-1001-01G

Bolt, oil pan to cylinder crankcase

M6

Nm

9

9

9

M8

Nm

20

20

20

M10

Nm

-

-

-

BA01.45-P-1002-01G

Bolt, transmission bell housing to oil pan

Nm

40

40

40

Number

Designation

Engine
272, 273
in model
211

BA49.10-P-1005-01T

Nut for exhaust rubber mount bracket

Nm

20

BA49.10-P-1006-01T

Bolt, catalytic converter bracket to transmission

Nm

20

BA49.10-P-1007-01T

Nut connecting catalytic converter bracket to catalytic converter

Nm

20

Number

Designation

Model 211

BA41.10-P-1001-01A

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

M10

Nm

40

M12

Nm

60

Number

Designation

Engine
271 in
model 211

BA49.10-P-1004-01K

Nut connecting front exhaust system to bracket

Nm

20

BA49.10-P-1005-01K

Bolt connecting bracket of front exhaust system to transmission

Nm

20

BA49.10-P-1010-01K

Bolt connecting exhaust manifold with catalytic converter to bracket

Nm

20

BA49.10-P-1011-01K

Bolt, catalytic converter bracket to transmission

Nm

40

Number

Designation

Engine
646.8

Engine
646.951/
961/962/
963/966 without code 474

Engine
646.951/
961/962/
963/966 will
Code 474

Engine
647

BA49.10-P-1001-01I

Self-locking nut of catalytic converter bracket to three way catalytic converter

Nm

20

20

20

20

BA49.10-P-1002-01I

Bolt of three way catalytic converter bracket to transmission housing

Nm

20

20

20

20

Number

Designation

Engines
112, 113
in model
211

BA49.10-P-1011-01A

Bolt of three way catalytic converter bracket to transmission housing

Nm

20

BA49.10-P-1012-01A

Self-locking nut of catalytic converter bracket to three way catalytic converter

Nm

20

Number

Designation

Trans-mission
716.6

BA26.10-P-1001-01C

Bolt, transmission to engine

Nm

40

Number

Designation

Trans-mission
716.6

BA26.40-P-1003-01C

Oil filler plug

Nm

35

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

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11