Remove/install transmission

AR26.10-P-0020TA

Remove/install transmission

19.11.09

20.6.08

Note on pilot bearing inserted

Step 19

 

Remove/install



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Disconnect battery ground cable

AR54.10-P-0003T



Notes on battery

AH54.10-P-0001-01A

2

Move gearshift lever into position "N"

3.1

Remove rear part of bottom part of noise encapsulation

Vehicles with diesel engine

AR94.30-P-5300T

3.2

Remove rear section of lower engine compartment paneling

Vehicles with gasoline engine

AR61.20-P-1105T

4

Remove retaining bracket (1) of rear bottom part of soundproofing

Vehicles with diesel engine

5

Remove three way catalytic converter bracket (2)

 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

6

Remove O2 sensor downstream of catalytic converter

Engine 112, 271

Engine 271

AR07.52-P-5303TK

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

AR14.00-P-5303T

7

Remove front catalytic converter bracket on transmission (6)

Engine 271



*BA49.10-P-1010-01K



*BA49.10-P-1011-01K

8

Detach ground line (3) from transmission (6)

9

Remove cover (4)

 Installation: Insert lug (4a) of cover (4) in recess clearance (4b).

10

Disconnect hydraulic pump connector (11) and ASG connector, 18-pin (X22/17)

11

Detach pipe (5) from transmission (6) and engine oil pan

Engines 646, 647



*BA01.45-P-1001-01G



*BA01.45-P-1002-01G

12

Support and lash down transmission (6)

13

Remove rear engine support (7) together with rear engine mount (8)

AR22.10-P-1160T

14

Remove flexible coupling (9)

 Check flexible coupling (9) for wear and damage

AR41.10-P-0050-02T



*BA41.10-P-1001-01A

 Installation: Mount propeller shaft (106) on transmission (6).

AR41.10-P-0050-07I



*BA41.10-P-1001-01A

15

Loosen fitting sleeves of flexible coupling (9)

AR41.10-P-0050-09DA



Drift for loosening fitting sleeves in flex disks.

WF58.50-P-4110-01A

16

Tie up the propeller shaft (106) securely at the front brake cable

17

Lower transmission (6) slightly and remove bolts (10)



*BA26.10-P-1001-01C

18

Support engine at the engine oil pan

 When taking out the transmission (6) the engine must not tilt at the splash wall otherwise the brake lines routed there will be damaged.

19

Remove transmission (6) from below

 Installation: In order to avoid damage to the pilot bearing, carefully insert transmission (6) with input shaft into pilot bearing without tilting.



Checking

20

Check pilot bearing in flywheel

 The flywheel must be replaced if it runs noisily and/or roughly and exhibits wear.

Engines 646, 647

AR03.30-P-8001T

Engine 112

AR03.30-P-8001C

Engine 271

AR03.30-P-8001TK

21

Check central clutch operator

 The central clutch release bearing must be replaced if it runs noisily and/or roughly, is leaking and exhibits wear.

AR26.40-D-0345A

22

Inspect transmission oil level

 The oil filler screw is only accessible after removing the pressure reservoir:



Remove pressure reservoir.

AR26.60-P-0015T

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

 Carry out measurement with angled hexagon socket wrench.



*BA26.40-P-1003-01C



*BF26.10-P-1001-01C

23

Install in the reverse order

24

Check hydraulic fluid level; correct if necessary

AR26.60-D-0009A

25

Teach in gears with STAR DIAGNOSIS

Number

Designation

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

BA49.10-P-1002-01I

Bolt of three way catalytic converter bracket to transmission housing

Nm

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

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 646.951/
961/962/
963/966

Engine
647

BA01.45-P-1001-01G

Bolt, oil pan to cylinder crankcase

M6

Nm

9

9

M8

Nm

20

20

M10

Nm

-

-

BA01.45-P-1002-01G

Bolt, transmission bell housing to oil pan

Nm

40

40

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

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