Bert Rowe’s-mercedes-Benz ‘A’-class info. Gearbox (Manual) Dumbbell replacement, loss of gears , gear…

18 May 2015 | Author: | Comments Off on Bert Rowe’s-mercedes-Benz ‘A’-class info. Gearbox (Manual) Dumbbell replacement, loss of gears , gear…
Mercedes-Benz A-Class

If you have Gearbox problems follow any form of repair involves jacking the front of the car up, ie track rod ends, lower ball joints replacement then please read e-mail from Chris doing anything further it may save you hundreds of ЈЈЈ, see Mypage 29 where a similar occurred. :-

Hi lofty

Sorry for the have received your and tools many Thanks.

Ps is a fantastic help.

I have purchased a Mercededs A160 with a known gearbox which I was hoping was not too serious.

It was out of gear randomly and in any gear.

Had myself to drop the engine and the gearbox, This I did and may I add it is not a simple

Anyway once engine was out ( I had your article on replacing links) and read about the who’s drive shaft had out and experienced a similar problem to all be it a sudden loss of gears in his

So I started to look at this and to think this was a very problem but part of the shaft did not off. The more I looked at my ( the bits off history I got with the car a bill for a suspension strut on the passenger side 4 months Also when I pulled on the shaft it popped out too easily, and was a oily deposit all around the off the drive shaft location gearbox.

I then took the that this was the problem and put the back into the car making the drive shaft was fully into the gear box. replacing fluids and reverse the clutch (Ps it is an Automatic clutch)(ACS) .

And what the problem is sorted it has not out of gear since.

Have some picys to go with

Again Thanks for the website..

Fuller

The above Photo by Chris clearly shows either the drive shaft oil has gone defective /been or the drive shaft is not correctly if you have such leaks check the correct location of the shaft before going .

My ‘A’ Class first February 2002 is fitted a 5 speed manual gearbox. ref having a chassis number

The gear box shown in the photo is an but the basic shape, and location are the

When seeking spares for the box you will be asked for the chassis of your car, there are a of different numbered gear fitted to the ‘A’ Class.

do not ask me the differences are but these boxes are numbered for the different chassis or VIN The information I have shows all those listed which are boxes have a capacity of

Automatic boxes start the pre-designation number of 722 and have a larger capacity for obvious

This photo shows the removed and split from the the hydraulic thrust bearing is fitted.

The removal of this unit is of course necessary the clutch assembly needs this is only possible the engine lowered from the car which for most owners it a commercial garage job.

Gear Box

Two holes can be seen on the O/S of the gear box, It is logical the lower one B is the drain plug and the A the filler/level plug. In this day and age it is for gear box oil to be drained unless a dismantle/service of the gearbox is required.

If you are to check your gear box oil ensure the car is level. If on ramps the car will need to be leveled, the upper plug, its normal for the oil to be with the threads at the bottom of the location hole when the amount is installed, a few drops may away from the gearbox as the is removed. HOWEVER I did not level my car and so the oil removed and replaced with a measuring jug Do not try and overfill.

If top up is required, if use the same Gear oil, MB 75W-80W MB part/invoice/ number MA 001 989 26 -020201 trans fluid/gear oil . litre plus vat I could no details of this in the hand or service records.

Please other models of ‘A’ along with automatic may use a different grade of gear oil or as well as quantity of fluid, check the spec for your of ‘A’ Class with against you chassis number replacing or topping up the gearbox. what I can see all the above manual fitted to the ‘A’ Class 1.8.litres. However it would be to just confirm with MB purchasing the gear oil, the capacity of gear oil is in your gearbox is.

I have had my car now for just over years and am a member of the www.baby-benz.com club to date I have not of problems with the manual box, with the exception of the

However automatics are a different

The ones that have trouble appear to be around the miles mark. This is a problem to Mercedes-Benz which appear to have chosen to do or nothing about, albeit have offered some assistance to some owners who the work done within company.

There was one case in of which I have photographs, because Mercedes-Benz anti corrosion additive had not been /replaced at the prescribed time a corroded in the gearbox requiring the to be removed, gearbox stripped and relatively cheap valve even in Brazil it cost to a Ј1000. Such work in the UK be almost prohibitive by cost, and it be cheaper to fit a new automatic gearbox several thousand pounds the labour and vat. So be warned use MB cheap imitations can cost you of ЈЈЈЈЈЈЈЈЈ

Linkage see below,

The problem I am aware of is the fact a number of owners have that there gearbox is not to the correct level.

My own car has had a very whine in 3rd gear for some and so I decided to check the gearbox oil

This is not an easy task as you to safely get under the car, and the car to be level, the only other way to the DIYer is with the vehicle on drain and measure the gearbox

As this was the only option to me without garage costs I to change the fluid. I purchased two containers of Gear oil /fluid at Ј13 66 a plus vat and set about the job.

The problem was locating a 14mm key to remove the plugs, filler and Because of the limited space I made up an adaptor from a nut with a deep head and locked two 14mm nuts on the shank so that I could use a ring spanner. Note both plugs were tight, the filler plug so so that I had to put the electric heat gun on the before I could move it.

in mind that these plugs are situated in an aluminium case which is not the most metal in the World, take not to damage of crack the casing.

removed the plugs I drained and the fluid. I removed 1.41 when in fact the box should contained 1.8 litres the drained was also much darker in than the new fluid, so the time changing it was well worth

Getting the new gear oil from the can was easy, I used one of the caps the centre and pushed a polythene through the cap, ensuring it was a fit, I placed this on one of the containers and allowed it to run into the gearbox under gravity, I did to withdraw the tube a couple of to allow air to enter the plastic as the vacuum created prevented the leaving the container. I then .8 of a litre to the now empty container and put into the gearbox using the method.

I am now confident that my not only has the correct quantity of and that it has also been

Remember to reseal the plug/plugs refitting. I used PTFE rather than ‘Loc-Tite’ if do ever have to come out hopefully they will not be so

Gear box selector linkage

box selector linkage, best well alone, but be aware of it is if you are unable to engage 3rd and 5th gears the could well be due to this or detached link

Having the link which will you just under Ј3.00 it is fitted, However Tony, one of my has recently informed me that he had to use force to get the link to clip the small balls on which it something like ‘mole’ will make the job easy but do not do it or you will damage the link. properly engaged you will a click as the cup on the link snaps the ball either end.

It almost sounds as though MB altered the design. Lets hope so.

Once again car, a number of dry metal and no grease nipples! Nylon and fittings are less likely to lubrication but even they can against one another making movement stiff and less I use Silicone spray on plastic, fittings and a small amount of slip grease on metal parts, only you can decide you do the same, but it certainly does no

These are e-mails received fellow owners who have a fortune by reading the information on site along with the in particular relating to the link

These are genuine e-mails the are in some cases alarming you consider you are paying Ј85-Ј100.00 per for the expertise of Mercedes-Benz staff

Dear Lofty,

You have me a small fortune and I am eternally I lost 3rd 5th gears on the way back Wales last week so I my car to my local mechanic. He could see no but said he would ring the Mercedes dealer for advice and let me

Mercedes dealer said had no experience of this problem and stripping the gearbox for further – I thought expensive.

a little about cars I was not that this was in my best as there were no strange from either gear box or and that gears 1,2 4 all worked

I posted a question about heating elements in the front on the Baby-Benz web site a few weeks ago little response but in desperation a plea for help about the and thankfully you answered.

You were spot on. I printed the picture and the number details and two days I had a bill for Ј20 and a perfectly working again. Thank you once

Stephen Philippa Unquote

Thank you.

After panic, shaking of heads mechanical colleagues, and rubbing of of garage owners we have 3rd and 5th again. We have an A140 A which lost the use of 3rd and 5th gear. Our option was to top up oil in gear box (cheapest but after looking on the baby-benz for help in locating the filler I came across your the page on the gearbox and the item on the LINKAGE.

Again thanks for being there, the right at the right time. Regards, Russell

Unquote

Hi, Just a line to tell you what a site you have put together. You possibly saved me the cost of a new It was the 3 pound linkage on the 3rd and 5th gear.

I was I would have to shell out 6-800 pounds for a clutch but in the back of my mind told me the was ok. I just thought I would the forums and came across site.

Thanks Very Joe Cox unquote.

Quote

Having engaging 3rd and 5th gear on my A160 of I turned to your homepage as I bought the car as my families extra and I do not paying to much in repairs. to you I have been able to spark plugs and other actions.

So looking in the parts on I found the section on gear box linkage. I did run out to the car and looked on the top of the gear and yes (may be no) the plastic linkage was I cancelled my time at the Mercedes and ordered the spare part for a more than 4 Euro.

I went to collect it and then it was an task to fix the problem. The only to add is that I wasn’t totally out of and third gear, sometimes worked, I guess due to the the part were swinging freely on the I also agree that it is to be careful applying the part, I a tool.

Well, thank you much for an excellent page

Anders Jцrle Stockholm. Unquote

So if you experience this do not be conned by some ill informed be it a Mercedes Benz garage or not in selecting 3rd 5th gears as has been by several a number of A class as well as Phillipa above, can be at a very expensive excuse to work on your car. you commit, check to ensure the link marked A is still in if missing it can be replaced from MB part Number MA 000 993 01 61 Ball Costing just under 18/04/06 with the VAT and a DIY repair save you pounds.

You can see the linkage just by lifting the and looking in the direction of the arrow, so could save you a lot of money, as as anxiety, Come to that why not me, carry a spare you have to loose at that price.

has also brought to my attention this self same is fitted to A class fitted the ACS transmission, the only difference was he also lost the use of 4th gear as so do not get caught out investigate the location of vulnerable link and carry a it could save you a lot of time and a lot of in getting your car transported to a who if are as knowledgeable as Mercedes Workshops want to remove and replace transmission, Frightening.

Gear Linkage

Unlike most boxes the gear lever not go into the top of the gearbox but into a selector mechanism, this in operates cables which are to the top of the gearbox selector, this can be when lifting the bonnet, the change of gears is finally

Controls buttons which the cables.

Situated on the top of the gear mechanism, under the leather stick surround are two Orange push buttons, these the mechanic/owner to adjust to cables in to the gearbox selector; with selected, when these are pressed the gear lever can be re-set ensuring that all are easily obtainable.

(I would stress that I have not had to my car in respect of this adjustment and cannot therefore state what action they when using these However you do not need to be a mechanic to see they play a part in the of the gear lever selection

If ordering parts for your car use the Vin number this will you get the correct parts for you model and

To access the orange reset you will need to remove the gear lever surround, is best done using wedges, plastic cycle levers are ideal, ease the up evenly ensuring the leather is not cut or

To replace ensure the leather is on the plastic frame, position and push down until it is to clip into place.

ease the leather sleeve up the lever knob until you can the locking collar.

Removing the lever knob

I can’t how many times I have this question asked, it every body for some wind’s to remove the gear knob, however when I was this question again week I forwarded it on to Tony, a owner who I knew had successfully the knob from his gear

Some months ago I attempted to guidance I have but gave up as I get the component indicated in the instruction to the knob from the lever.

I began to question whether the two ‘A’ class models and post face lift different, there are known such as the central heater for bulb replacement, so I was cautious as components are easily damaged when the plastic is cold and Also Tony’s car was pre-face

You should now be able to turn the anti clockwise, however was very tight. you would a better chance while the is warm or gently heat a heat gun or hair dryer but care, better still the job until the weather is warm or the car is at warm throughout.

As seen the underside of the leather sleeve the collar is turned anti-clockwise to the gear lever from the stick.

However today I had another go this time the rubber gasket that around the gear lever has on my car and I wanted to replace it with an dust excluder, attempts to the correct replacement part already failed so it was a case of

However undoing the locking was difficult because it was so tight, I eventually by wearing a rubber which gave me more

having exposed the lever and the knob I was able to fit an improvised over the exposed selector in my case I used the rubber off of a link swivel joint was ideal the hole in the centre just the right size for the stick. I then fitted a washer which holds the firmly in place.

The insert photograph is the part of the gasket that had split and

This is to be expected as the rubber is in all directions as the various gears are

I also spray lubricated the linkage while it was exposed 3 in 1 light oil.

The two gear selector cables enter the car at the /lower fire wall. then travel through the tunnel to the gear lever

light switch

Yes the reversing switch is located in the gearbox away from the link in the linkage for the gear selection.

I indicated it is location with a arrow. The item that can be seen is the switch electrical I found that removing the connector was easiest carried out the car in 4th gear.

However having the connector see the warning Note before going further.

1 and 2 It is familiarising your self the connector that is attached to the master cylinder reservoir, as connector is exactly the same, the of the clip are pressed, which the connector to be removed.

Having the connector be aware that it be correctly re-located for the plug to and the clip to lock 2 3

To date I not had the need to remove or replace my However ‘dgc’ a fellow member has, He adapted a reach 22mm socket he has to shorten to fit under the cables the gearbox, my advise to anybody this is to use the New switch to adjust the the switch is not unlike a plug and if you the socket too much it will not the hexagon section of the switch you obviously need to engage to and re-fit the switch.

ADVISORY

Another of our Owners ‘Shaggy’ in the know has also warned the reverse gear MUST be

He says:- quote Ensure you only fit or remove the reversing switch with the reverse selected and do not take the gear out of until the job is completed (switch and tightened )the reason for is long and complicated but if you do it without the in reverse it may well end up requiring a new mechanism so you have been unquote

One owner caused some real problems by the switch out without selecting gear. Having replaced the he was not able to get 5th gear, this was as the switch was removed a plate in the box selector mechanism moved the gear being selected. He had to the selector and manually move the back into the position it when the switch is fitted in the position.

He was fortunate in being to do the job himself others may be less so Please observe this rule or leave to job to the professionals you will at least have back if the job satisfactory on completion. test the light before you away from the garage.

OH yes make the same mistake and has arisen more than so take great care to the above procedure If you do not you are going to yourself real problems.

made the mistake so now what!

photo shows the selector which is located by the gear cables, which is situated on the top of the assembly.

Plate A moves if the is moved with the switch

Or the switch is removed without reverse gear. This affects the selection of gears and need to be corrected before the switch will operate or gears can be obtained as normal.

Up and David a fellow owner me there was no option but to remove the (30/4/2010 now see below) re-site the and re-assemble, however this is not easy as there is nothing to the plate in position while the is re-assembled. David has as a result up with an easy answer does not require the selector to be by using a small pen telescopic to pull the selector plate into the correct position. His for doing so is available here:-

Bearing in mind that situation will only if the switch is removed without the transmission being placed REVERSE gear.

1. Select

2. Remove the newly installed switch.

3 .Using your Pen by placing it through the switch hole, raise the ‘PLATE’ A in the photo above,

4. Secure or get a party to hold in position reverse gear is selected in the

5. Remove the magnet.

6. Replace light switch.

Mercedes-Benz A-Class

7. Test, Job done.

I’m sure if you have made to error of the switch without selecting gear you will want to David for enlightening us all in his method of what is a very difficult and one that Mercedes Workshops want to make the most of if you your car to them for repair.

came up with this after having had to remove the to cure the fault on his car a difficult and consuming job, which is avoided.

Aug 2011 Are you better you work done by Mercedes

I received a mail from a owner, his car has been into a Workshop in Main land who have changed his reversing switch, only to find when he collected the car the reversing was still on, even though the new had been fitted.

he was now requesting as the garage said the cause was now a selector .

I mailed him back and if he had also lost the use of some yes he had but at the time of mailing wasn’t of it, he now even more distressed.

I him Explaining that the garage had not the Mercedes Benz work procedure to fit the switch and that was now ever chance the selector be damaged.

To my astonishment the garage him that moving the gear to reverse gear when the switch was optional and that had not damaged anything.

We exchanged mails with me suggesting unless the garage sorted the they had now caused, he would be taking the car to another MB garage and giving the bill to the MB repairer who did the and caused the damage.

They had suggested that it might pay him for me to go to to fix his car if I new better than they!

now sent him the file which states reverse gear be selected and maintained throughout the or the selector will be damaged, now decided to take another at his car at no cost to him, and yes they and found the selector damaged but in that the lever that you going into reverse inadvertently was bent but could be

On returning the selector and having the correct procedure the second around all was well and the light now off when other than gear is selected

So be warned happened before it will again, the gear lever be placed in reverse position and there throughout the repair. to do that and you like this will almost certainly the selector. If getting the work at any Garage you would be well to tell them of the procedure or you well suffer the same problems.

The photo right the selector, with switch on the plate B it believed that the was cussed in the area of C I myself it was simply a case of re-locating the which allows 3rd and 5th gears to be and the switch to operate and thus the light to illuminate when is selected

If you are having difficulty in gears

If you are having difficulty in gears then try this procedure:- Published by SVC Sergio, if you like to join the SVC site then mail :-svcglobal@svcglobal.com them you user name a request to join them and will return you a password will enable you to post and questions.

Sergio posted the information on MB ACS (clutch-less) and manual boxes.

Intrigued with the of this procedure, he personally did and found that the suggested does work and due to its importance I it would be valuable to owners if I it on his site, As we both have a aim I know he will not mind me it to this page.

This reset is a must to who suffer the old issue of difficulty in first and/or reverse ACS

Note ensure the car is on level or chock wheels as necessary.

1. the hand brake lever. On

1a. the ignition key on but do not start the engine.

2. the brake pedal.

3. Engage the gear, you may hear clicking the wing. This is the actuator moving within the ACS module.

4. to gear lever to neutral

5. Release the brake pedal.

6. the brake.

7. Engage the rear (*)

8. Return to gear lever to (*).

9. Finally release the pedal.

10. Release the hand lever, turn off and remove the key .

11. Re-apply hand brake chocks

Even with the off, the clutch auto is always energized but in this and following the script above, it learn the correct position of the drive plate.

So, if you let your play with the gear or even yourself move the lever just for fun and without the brake pedal, in the reality, you (or children or anyone else) are all the system.

Remember that fully computerized electro-hydraulic is very delicate and a complex not a toy and should be used only for

Do not ever play with the lever and do not allow to anyone to do if the engine is off.

For the fully system, do the same but, of brake pedal, use the clutch

Sergio.

John’s noisy

This photo shows the bearings that were the noise in the johns gearbox,replaced new and the noise is gone.

Mercedes-Benz that the oil in the gearbox does not replacing, however in my experience it is while changing this oil and it is to the correct level.

With the car on standing ,top filler removed, the oil should be up to the bottom of the filler hole.

It is worth the amount you remove if changing the if only to prove that the oil is low as it was in my own case.

The oil drains easier the Gear box lower plug if the fluid is warm I.e. a run.

This show the gear and differentional housed in of the gear box casing.

This the gear selector removed the top of the gearbox, it is this unit the the reverse ing light switch. To this unit from damaged while changing the lamp switch the gearbox be placed into and remain in gear until the new switch is fitted.

See above if you have fallen foul of this

This photo shows the shafts and gears positioned.

shows one of the syncromesh rings into the gearbox which drivers to move from one to another smoothly.

Prior to gears being fitted to boxes the engine and thus speed had to be judged by the driver to the gears grinding (Crashing) on e another as they tried to one to the other.

Commercial vehicles the last to be fitted with and thus the term crash was used by drivers, an alternative feature was to double-de-clutch

the clutch was the gearlever was moved to neutral the was again depressed and the next selected, providing the engine was correct a smooth change of could then be made no noise.

These days the clutch is not required many including commecial, being all manual gearboxes are now fitted syncromesh gears.

This shows the Gearbox partially

Thank you John Interesting you saved yourself a fortune.

in passing John also that the injectors on this car had been leaking which as much work again, having the engine out of the car made the job and he was able to do both repairs at the time.

The tool made by for fitting the poly V belt can be on page 57. along with an re-seating tool on page.98.

The of Mechanic all ‘A’ class should come complete

Mercedes-Benz A-Class
Mercedes-Benz A-Class
Mercedes-Benz A-Class
Mercedes-Benz A-Class
Mercedes-Benz A-Class
Mercedes-Benz A-Class

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