Manual gearbox Mercedes Vito 1 (W638)

Removal and installation the gearbox
Cars with engines 111.948 and 601.970 Removal 1. Disconnect the negative cable from the battery. 2. Remove the front wheels. 3. Remove the wiring bracket 4 (see figure...

Disassembly and assembly of the gearbox
Cars with engines 111.948 and 601.970 Removal 1. Remove the gearbox. 2. Remove the left flange 10 (see figure 6.10). Figure 6.10. Disassembling and assembling the...

Reverse light switch
Removal 1. Wipe the surface around the switch S19 (see figure 6.16). Figure 6.16. Reverse light switch: S19. Reversing light switch, S19.1. Reverse light switch wiring...

Bearing caps
Removal 1. Remove the lower engine guard. 2. Unscrew and remove bearing cover 1 together with oil guides 2 and 3 (see figure 6.17). Lubricate the bolts 4 with Loctite...

Clutch housing
Cars with engines 111.948 and 601.970 Removal 1. Disassemble the gearbox. 2. Remove the rotating shaft seal 3 (see figure 6.18). Figure 6.18. Clutch housing (cars with...

Gearbox housing
Cars with engines 111.948 and 601.970 Removal 1. Disassemble the gearbox. 2. Remove the rotating seal 9 (see figure 6.21). Figure 6.21. Gearbox housing (cars with...

Gearbox axle shaft seals
Removal 1. Drain the oil from the gearbox. 2. Remove the left 6 or right half shafts (see figure 6.24). Figure 6.24. Gearbox axle shaft seals: 1. Right rotating axle...

Drive shaft
Cars with engines 111.948 and 601.970 Disassembly 1. Disassemble the gearbox. 2. Unscrew bolt 2 (see figure 6.25). Figure 6.25. Drive shaft (cars with engines 111.948...

Driven shaft
Cars with engines 111.948 and 601.970 Disassembly 1. Disassemble the gearbox. 2. Unscrew bolt 2 (see figure 6.34). Figure 6.34. Driven shaft (cars with engines 111.948...

Reverse gear shaft
Cars with engines 111.948 and 601.970 Disassembly 1. Disassemble the gearbox. 2. Remove the thrust pad 1, reverse gear 2 and needle bearing 3 (see figure 6.38). Figure...

Disassembling and assembling the differential
Disassembly 1. Disassemble the gearbox. 2. Disconnect the differential driven gear 2 (see figure 6.43). Heat gear 2 to approximately 100°C if necessary. Figure 6.43....

Reverse gear lock
Removal 1. Remove the gearbox. 2. Remove the clutch release lever and clutch release assembly (only on cars with engine 611.980). 3. Unscrew plug 1 in clutch housing 4...

Adjusting the gear shift lever
1. Remove the ashtray. 2. Set the gear shift lever to neutral position. 3. Check and adjust distance A (see figure 6.45). To adjust, loosen nuts 1 and 3 and turn...

Gear shift cables
Removal 1. Remove the rear air duct. 2. Remove the ashtray. 3. Disconnect the gear shift cables 2 from the gearbox (see figure 6.46). Figure 6.46. Gear shift cables...

Technical characteristics of mechanical gearboxes
Transmission SAA 503.018/01, designation - GTO 24-5/3.769-0.721, used on 108D (113) vehicles with OM 601.942 (111.948) engines Filling capacity: 2 l. Transmission SAA...

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Vito 1 (1996-2003)