Remove/install transmission - AR26.10-P-0020P

TRANSMISSION 716.6 in MODEL 203, 209.3 /4 

Fig 1: Identifying Transmission Remove/Install Components - Model 203, 209.3 /4

Shown on transmission 716.6 with selector cable 

Fig 2: Identifying Refrigerant Line - Shown On Transmission 716.6 With Selector Cable

	Remove/install
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	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
	Risk of explosion  caused by oxyhydrogen gas. Risk of poisoning and caustic burns  caused by swallowing battery acid. Risk of injury  caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries	No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and goggles. 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	Disconnect ground line from battery	Insulate ground line as a protection against unintentional contact of detached ground line with ground point of battery.
		Model 203	AR54.10-P-0003P
		Model 209	AR54.10-P-0003Q
	Notes on battery		AH54.10-P-0001-01A
2	Remove air filter housing
		Engine 111.951	AR09.10-P-1150PR
		Engine 111.955 Engine 111.981	AR09.10-P-1150PK
		Engine 112.912 /946 /955 /961 Engine 112.916 /953	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 lubricate rubber guides for assembly.	*BR00.45-Z-1001-06A
3.1	Remove lower engine compartment paneling	Vehicles with gasoline engines	AR61.20-P-1105P
3.2	Remove bottom sections of soundproofing capsule	Vehicles with diesel engines	AR94.30-P-5300P
4.1	Remove rear exhaust system	Refer to: Exhaust system, removal and installation of complete system:
		Engine 111	AR49.10-P-7000PR
		Engine 112	AR49.10-P-7000PV
		Engine 271.921 /940 /946 /948 /955	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, remove the bolts (14) and nuts (15).
6	Remove bolts (21) and place refrigerant line (22) to one side	Model 209
		Mark the installation position of the refrigerant line (22).
7	Detach front propeller shaft (17) from transmission (1)	The flexible coupling remains on the front propeller shaft (17).	AR41.10-P-0050-02EA
		Installation:  Attach the front propeller shaft (17) to the transmission (1).	AR41.10-P-0050-07EA
			Fig 3
8	Undo fitted sleeves of flexible coupling and slide back front propeller shaft (17)		AR41.10-P-0050-09DA
	Prepare drift for loosening fitted sleeves in flexible couplings.		WF58.50-P-4110-01A
9	Separate plug connection of reversing light switch (X49/1)
10	Disconnect hydraulic line (11) of clutch operation		Fig 4
	Brake fluid notes		AH42.50-P-0001-01A
11	Support transmission (1) with transmission lifter and lash down securely	Refer to GOTIS http://gotis.aftersales.daimlerchrysler.com  Refer to GOTIS http://gotis.aftersales.daimlerchrysler.com
12	Remove engine support (12) with engine mount; to do so, remove bolts (16, 19) and detach ground line (20)	The engine mount remains on the engine support (12).
		Engine 111 except 111.981, engine 112 except engine 112.946 in model 203.064/ 264 Engine 271.921/940/946/948 in model 203 Engine 271 in model 209 Engine 646 in model 203, 209 Engine 112.946 in model 203.064/ 264	AR22.10-P-1160PR
		ENGINE 611, 612 in model 203 Engine 612 in model 209	AR22.10-P-1160HC
		Engine 272.920 in model 203.052 /252 /752 Engine 272.940 in model 203.054 /254, 209.354 /454 Engine 272.960 in model 203.056 /256 /756, 209.356 /456	AR22.10-P-1160QB
		Engine 642 in model 203, 209	AR22.10-P-1160PI
		Engine 112 in model 203.081 /084 /281 /284 Engine 272.970 in model 203.087 /287 Engine 272.941 in model 203.092 /292 Engine 111.981 in model 203.747 ENGINE 271.942 in model 203, 209	AR22.10-P-1160PW
	Perform operation steps 13 to 17 on transmissions with selector cable
13	Release locking pin (3) and pull out
14	Detach shift rod (5) from ball head on transmission (1)	Installation:  Grease ball joint lightly.
		Long-life grease	*BR00.45-Z-1001-06A
15	Detach cap (18) from bracket (8)	Installation:  First insert upper guide of cap (18), 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:  Apply a thin coating of grease to 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 transmissions with single-rod gearshift
18	Detach shift rod (5) from transmission (1)		AR26.60-P-0600-02V
19	Detach pipe from engine oil pan	All except engine 642
			*BA01.45-P-1001-01A
			*BA01.45-P-1001-01B
			*BA01.45-P-1001-01H
			*BA01.45-P-1002-01M
			*BA01.45-P-1001-01G
20	Unscrew bolt (2)		*BA01.45-P-1002-01A
			*BA26.10-P-1001-01C
			*BA01.45-P-1002-01G
			*BA01.45-P-1006-01H
21	Turn lead pipe down out of the way	All except engine 642
22	Remove transmission (1) downwards at an angle
23	Check thrust bearing and deep-groove ball bearing of crankshaft
24	Install in the reverse order
25	Check transmission oil level; correct if necessary	Correct oil level = 10 mm below bottom edge of filler opening. Carry out measurement e.g. with angled hexagon socket wrench.	*BF26.10-P-1001-01C
	Filling capacity of transmission oil revised		BT26.00-P-0001-01A
			*BA26.40-P-1003-01C
			*BA26.40-P-1004-01C
26	Bleed clutch operating system		AR25.20-P-0070P
27	Check shift mechanism for ease of movement	On vehicles with transmission (1) with selector cable (7) if shift mechanism is sluggish: ↓ Adjust selector cable (7): Vehicles up to approx. 06/2000
		Model 203 Vehicles as of 06/2000	AR26.60-P-0635-02D
		Model 203, 209	AR26.60-P-0635-02E
28	Perform basic programming	Model 203	AR00.19-P-0200P
		Model 209	AR00.19-P-0200Q
29	Read out fault memory with STAR DIAGNOSIS and erase if necessary	STAR DIAGNOSIS diagnosis system
	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	Perform engine test run and check transmission (1) for function and leaks

OIL PAN

OIL PAN

OIL PAN

OIL PAN

OIL PAN

OIL PAN

MANUAL TRANSMISSION COMPLETE

HOUSING

TRANSMISSION COMPLETE

Fig 3: Identifying Torque Wrench (001 589 66 21 00)

Fig 4: Identifying Set Of Stop Plugs (129 589 00 91 00)