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 gearbox (cars with engines 111.948 and 601.970):
1. Rear cover of the reverse shaft,
2. Guide pipe,
3. Retainer,
4. Clutch housing,
5. Gear shift unit,
6, 16. Ball,
7, 17. Spring,
8. Gear shift lock cover,
9, 13, 15, 19. Bolt,
10. Output flange,
11. Retaining ring,
12. Bearing cover,
14. Gearbox housing,
18. Gear shift lock lock bolt,
S19. Reversing light switch.
3. Remove the clutch.
4. Remove guide tube 2.
5. Remove the rear cover 1 of the gearbox.
6. Remove gear shift lever 5.
7. Unscrew bolt 19.
8. Unscrew cover 8 and remove spring 7 with balls 6.
9. Unscrew plug 18, remove spring 17 and ball 16.
10. Remove the reversing light switch S19.
11. Remove the bearing cover 12.
12. Unscrew bolts 15.
13. Remove the locking ring 11.
14. Disconnect the gearbox housing (if necessary, using a screwdriver), preheating it to a temperature of 80-100°C.
15. Remove the drive 22 and output 21 shafts together with the gear shift forks 20, 23 and 24 together with the clutch housing (see figure 6.11). Fork 27 must be in neutral position (see figure 6.12). Insert 40mm spacer.
Figure 6.11. Disassembling and assembling the gearbox (cars with engines 111.948 and 601.970):
20. Fork for engaging 1st and 2nd gears,
21. Output shaft,
22. Drive shaft,
23. 5th gear shift fork,
24. Fork for engaging 3rd and 4th gear,
25. Differential.
Figure 6.12. Disassembling and assembling the gearbox:
26. Reverse shaft,
27. Reverse gear engagement fork,
28. Separator.
16. Disconnect fork 24 from the guide on fork 20.
17. Remove forks 20, 23 and 24 from drive shaft 22 and output shaft 21.
18. Check the axial runout of the gears.
19. Disconnect the drive shaft 22.
20. Disconnect the output shaft 21.
21. Check the condition of the splines and bearings of the gears.
22. Remove differential 25 from clutch housing 4.
23. Disassemble differential 25.
24. Check the condition of the splines and bearings of the reverse gear shaft 26.
25. Remove the reverse gear cover on the clutch housing.
26. Remove the reverse gear shaft 26 from the clutch housing 4 using a punch. Remove fork 27.
27. Disassemble the reverse gear shaft 26.
28. Check the condition of the bearings in clutch housing 4 and disassemble it if necessary.
29. Check the condition of the bearings in gearbox housing 14 and disassemble it if necessary.
Installation
30. Installation is carried out in the reverse order of removal.
Cars with engine 611.980
Removal
31. Remove the gearbox.
32. Remove the support 10 of the gearbox (see figure 6.13).
Figure 6.13. Disassembling and assembling the gearbox (cars with engine 611.980):
1. Left flange,
2. Locking finger,
3. Locking bolt,
4. Gear shift unit,
5. Bearing cover,
6, 7, 8. Bolts,
9. Roller bearing,
10. Gearbox support,
21. Rotating shaft seal,
S19. Reversing light switch.
33. Remove the left flange 1.
34. Remove the clutch and plug.
35. Remove locking pins 2 from the gear shift forks. Replace locking pins 2.
36. Remove gear shift unit 4.
37. Remove the reversing light switch S19.
38. Remove bearing cover 5.
39. Unscrew bolts 8 and 7. Disconnect gearbox housing 16.
40. Remove the input shaft 12, output shaft 11 together with gear shift forks 13, 14 and 15 together with the clutch housing 16 (see figure 6.14).
Figure 6.14. Disassembling and assembling the gearbox (cars with engine 611.980):
11. Output shaft,
12. Drive shaft,
13. 5th gear shift fork,
14. Fork for engaging 3rd and 4th gears,
15. Fork for engaging 1st and 2nd gears,
16. Gearbox housing,
17. Differential.
41. Disconnect gear shift forks 13, 14 and 15c of the input 12 and output 11 shafts.
[Article was obtained from the portal: MercedesMAN.ru]
42. Check the axial runout of the gears.
43. Disassemble the drive shaft 12.
44. Disassemble the output shaft 11.
45. Check the condition of the splines and bearings of the gears.
46. Remove differential 17 from clutch housing 16.
47. Disassemble differential 17.
48. Remove the reverse gear engagement fork 20.
49. Remove reverse shaft 18.
50. Check the condition of the splines and bearings of the reverse gear shaft 18.
51. Disassemble the reverse gear shaft 18.
52. Check the condition of the bearings in clutch housing 19 and disassemble it if necessary.
53. Check the condition of the bearings in gearbox housing 16 and disassemble it if necessary.
Installation
54. Installation is carried out in the reverse order of removal.
Figure 6.15. Disassembling and assembling the gearbox (cars with engine 611.980):
18. Reverse shaft,
19. Clutch housing,
20. Reverse gear engagement fork.