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Manual transmission — general description (Mercedes-Benz Sprinter 903)

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The Mercedes Sprinter is equipped with a five-speed gearbox G 16-5/4.898, designated 711.603. Some modifications use a gearbox of the G 28-5 type. This designation will be useful to you in case of replacing the gearbox with a used one.

Attention! At different stages of production, different types of oil were poured into the KP. Gearboxes with numbers up to 051 110 used SAE 80 transmission oil, and gearboxes with numbers starting from 051 110 used SAE 75W85 oil. Mixing these oils is not allowed. When changing transmission oil, you should fill in oil of the second grade. In this case, it is necessary to completely drain the oil of the previous brand from the gearbox.


Figure 185. Gear layout diagram for gears 1–5, as well as reverse gear (top) and gear shift diagram…

Figure 185. Gear layout diagram for gears 1–5, as well as reverse gear (top) and gear shift diagram (bottom)


The gears are engaged via the shift rod directly by the gear shift lever. Figure 185 shows the gear shift patterns.

Inside the gearbox, gear engagement is carried out by a rod, which, through separate forks, connects the engagement clutches to the gear pinions.

[Text republished from the website: MercedesMan.ru]

Two electrical devices are connected to the gearbox: the speedometer sensor and the reverse signal switch. The signal transmitted to the speedometer is taken from the driven bevel gear of the differential. The speedometer converts the received pulses and provides information about the speed. The reverse switch is activated directly by the reverse gear engagement fork.

The torque is transmitted via the clutch to the driven shaft of the gearbox. It contains the driven gears of 1–5 gears and the reverse gear gear. The gears are in contact with the gears of the intermediate shaft. When the gear shift lever is in neutral, the gears rotate freely. When a gear is engaged, one of the pairs of gears is connected to the shaft and the torque is transmitted to the driven shaft of the gearbox. The ratio of the teeth of the pair of gears forms the gear ratio. All gears, except reverse, are synchronized.
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Mercedes Sprinter / Mechanical gearbox
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Removal and installation the gearbox
Gearbox repair
Replacing the primary (drive) shaft seal of the gearbox
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Vario 814D (1996-2003, diesel) 
  • General information
  • Maintenance
  • Power unit
  • Engines 602.984/985
  • Engines 904.908/914/923/936
  • Transmission
  • Clutch
  • Manual gearbox 711.613
  • Manual gearbox 710.64/66
  • Manual gearbox 715.051
  • Automatic gearbox 723.345
  • Power take-off box
  • Chassis
  • Front suspension
  • Rear suspension
  • Steering
  • Brake system
  • Body and electrical equipment
  • Interior (internal elements)
  • Exterior (external elements)
  • Heater and air conditioner
  • Electrical diagrams
Vito 2 (2003-2014, diesel) 
  • General information
  • User manual
  • Maintenance
  • Diesel engine OM646
  • Engine repair
  • Cooling and lubrication system
  • Power and exhaust system
  • Transmission
  • Clutch
  • Car gearbox
  • Chassis
  • Front suspension
  • Rear suspension
  • Steering
  • Brake system
  • Body
  • Body elements
  • Electrical equipment
  • Equipment and devices
  • Security systems
  • Electrical circuits
Vito 1 (1996-2003) 
  • General information
  • User manual
  • Maintenance
  • Petrol engines 2.0 l
  • Engine repair
  • Lubrication system
  • Cooling system
  • Power and control system
  • Petrol engines 2.8 l
  • Engine repair
  • Lubrication system
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  • Power and control system
  • Diesel engines 2.3 l
  • Engine repair
  • Cooling system
  • Lubrication system
  • Turbocharging and recycling
  • Power and control system
  • Diesel engines 2.2 l
  • Engine repair
  • Cooling system
  • Lubrication system
  • Turbocharging and recycling
  • Power and control system
  • Transmission
  • Clutch
  • Mechanical gearbox
  • Automatic gearbox
  • Chassis
  • Front suspension and wheels
  • Rear suspension
  • Steering
  • Brake system
  • Body
  • Exterior (external elements)
  • Interior (internal elements)
  • Electrical equipment
  • Equipment and devices
  • Heater and air conditioner
  • Electrical circuits
Sprinter (1995-2000, diesel) 
  • General information
  • Introduction to the guide
  • Maintenance
  • Power unit
  • Engine repair
  • Lubrication system
  • Cooling system
  • Power and exhaust system
  • Transmission
  • Clutch
  • Mechanical gearbox
  • Automatic gearbox
  • Front axle
  • Rear axle and cardan
  • Chassis
  • Car suspension
  • Steering
  • Brake system
  • Tires and wheels
  • Electrical equipment
  • Equipment and devices
  • Headlights and lighting
  • Power devices
  • Electrical circuits
 
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