Freightliner AMT3 Service Manual

Freightliner AMT3 and Mercedes-Benz Automated-Manual	26.03
Transmissions

General Troubleshooting

IMPORTANT: Always use ServiceLink when attempting to diagnose problems with the AGS (Automated Gear Shift) transmission.

How To Start

To gain a baseline for troubleshooting when there is no de®nite problem, when the malfunction is erratic or intermittent, or to determine the general health of the electrical system, start with the electrical pre-test in Subject 301.

In a few cases there will be a de®nite problem and no J1587 fault code will be sent (engine will not crank, no information on gear display, ¯uid level fault). For these problems, see the appropriate table in Subject 301.

But in most cases, the J1587 fault code is the starting point for the troubleshooting procedures. See Table 1 to ®nd information for SID fault codes. See Table 2 to ®nd information for PID fault codes.

Before starting any procedures, use ServiceLink to depressurize the AGS hydraulic system. For detailed procedures, see Subject 160.

Fault Code Guide

To troubleshoot a given fault code, look up the subject number in Table 1 (for SIDs) and Table 2 (for PIDs). Follow the procedures for that fault code until the fault is corrected.

Fault Code Guide (MID 130 SIDs)

	SID	FMI	Text Message	Failure Reason	Procedure
	18	02	Prim Selector Erratic	The shift lever does not shift gears.	See Subject 302.
	33	03	MultiPress Ind Short Hi	The hydraulic pressure sensor circuit is shorted to power.	See Subject 303.
	33	04	MultiPress Ind Short Lo	The hydraulic pressure sensor circuit is shorted to ground.	See Subject 303.
	33	05	MultiPress Ind OPEN	The hydraulic pressure sensor circuit is open.	See Subject 303.
	52	05	Hydraulic Sys OPEN	The hydraulic pump circuit is open.	See Subject 304.
	52	07	Hydraulic Sys NoRESPONSE	The hydraulic pressure does not increase even though the	See Subject 304.
				hydraulic pump is activated.
	52	11	Clutch Act Not Known	The hydraulic pump temperature is too high.	See Subject 304.
	55	00	Clutch Act HIGH	The clutch is too hot.	See Subject 305.
	55	07	Clutch Act NoRESPONSE	The clutch does not operate properly.	See Subject 305.
	55	13	Clutch Act Calibrate	The clutch needs to be calibrated.	See Subject 305.
	231	02	SAE J1939 Datalink Erratic	The J1939 datalink is not communicating properly.	See Subject 306.
	231	09	SAE J1939 Datalink UPDATE	The J1939 datalink has timed out.	See Subject 306.
	231	12	SAE J1939 Datalink Bad	The J1939 datalink is not communicating with the	See Subject 306.
				transmission.
	251	00	POWER SUPPLY HIGH	The power supply voltage is too high.	See Subject 307.
	251	01	POWER SUPPLY Low	The power supply voltage is too low.	See Subject 307.
	251	05	POWER SUPPLY OPEN	There is no power to the transmission with the engine	See Subject 307.
				running.
	251	14	POWER SUPPLY RSRVD	The power supply is not properly grounded.	See Subject 307.
	253	02	Calibration Memory Erratic	The transmission needs to be recalibrated.	See Subject 308.
	253	12	Calibration Memory Bad	The transmission needs to be recalibrated.	See Subject 308.
	253	13	Calibration Memory Calibrate	The transmission needs to be recalibrated.	See Subject 308.
	253	14	Calibration Memory RSRVD	The transmission needs to be recalibrated.	See Subject 308.

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26.03	Transmissions
General Troubleshooting

Fault Code Guide (MID 130 SIDs)

	SID	FMI	Text Message		Failure Reason	Procedure
	254	04	Controller Short Lo		The TCU is shorted to ground.	See Subject 309.
	254	05	Controller OPEN		The TCU has an open circuit.	See Subject 309.
	254	11	Controller Not Known		The TCU AUTO mode software module has an error.	See Subject 309.
	254	12	Controller Bad		The TCU has a hardware problem.	See Subject 309.
	254	13	Controller Calibrate		The TCU has a software memory problem.	See Subject 309.
					Table 1, Fault Code Guide (SIDs)
					Fault Code Guide (MID 130 PIDs)
	PID	FMI	Text Message		Failure Reason	Procedure
	33	02	Erratic	The clutch position sensor gives invalid data.		See Subject 310.
	33	03	Short Hi	The clutch position sensor circuit is shorted to power.		See Subject 310.
	33	04	Short Lo	The clutch position sensor circuit is shorted to ground.		See Subject 310.
	33	05	OPEN	The clutch position sensor circuit is open.		See Subject 310.
	33	14	RSRVD	The clutch position sensor gives incorrect resistance		See Subject 310.
				readings.
	59	02	Shift FNGR Gear Erratic	The shift rod position sensor gives invalid data.		See Subject 311.
	59	03	Shift FNGR Gear Short Hi	The gear position sensor circuit is shorted to power.		See Subject 311.
	59	04	Shift FNGR Gear Short Lo	The gear position sensor circuit is shorted to ground.		See Subject 311.
	59	05	Shift FNGR Gear OPEN	The gear position sensor circuit is open.		See Subject 311.
	59	14	Shift FNGR Gear RSRVD	The gear position sensor gives incorrect resistance readings.		See Subject 311.
	60	02	Shift FNGR Rail Erratic	The rail position sensor circuit gives invalid data.		See Subject 312.
	60	03	Shift FNGR Rail Short Hi	The rail position sensor circuit is shorted to power.		See Subject 312.
	60	04	Shift FNGR Rail Short Lo	The rail position sensor circuit is shorted to ground.		See Subject 312.
	60	05	Shift FNGR Rail OPEN	The rail position sensor circuit is open.		See Subject 312.
	60	14	Shift FNGR Rail RSRVD	The rail position sensor gives incorrect resistance readings.		See Subject 312.
	64	09	Dir Switch Update	The output shaft speed sensor is not providing accurate		See Subject 313.
				directional information.
	64	11	Dir Switch Not Known	The output shaft speed sensor is not providing accurate		See Subject 313.
				directional information.
	158	00	Volts (BattSw) HIGH	The voltage in the ignition power circuit is too high.		See Subject 314.
	158	01	Volts (BattSw) Low	The voltage in the ignition power circuit is too low.		See Subject 314.
	161	02	In shaft SPEED Erratic	The input shaft speed sensor circuit gives invalid data.		See Subject 315.
	161	03	In shaft SPEED Short Hi	The input shaft speed sensor circuit is shorted to power.		See Subject 315.
	161	04	In shaft SPEED Short Lo	The input shaft speed sensor circuit is shorted to ground.		See Subject 315.
	161	05	In shaft SPEED OPEN	The input shaft speed sensor circuit is open.		See Subject 315.
	161	08	In shaft SPEED Update	The input shaft speed sensor circuit is broadcasting an		See Subject 315.
				abnormal frequency.

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Transmissions

General Troubleshooting

Fault Code Guide (MID 130 PIDs)

	PID	FMI	Text Message	Failure Reason	Procedure
	162	02	RANGE Selected Erratic	The transmission is not properly calibrated.	See Subject 316.
	163	02	RANGE Attained Erratic	The gears do not shift properly.	See Subject 316.
	191	02	OUTPUT SPEED Erratic	One or both of the output shaft speed sensor circuits give	See Subject 317.
				invalid data.
	191	05	OUTPUT SPEED OPEN	One or both of the output shaft speed sensor circuits are	See Subject 317.
				open.
	191	08	OUTPUT SPEED SIGNAL	There is no signal coming from one or both output shaft	See Subject 317.
				speed sensors.
	191	14	OUTPUT SPEED RSRVD	The output shaft speed sensor is providing invalid data.	See Subject 317.
				Table 2, Fault Code Guide (PIDs)

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Transmissions

Troubleshooting Without Fault Codes

IMPORTANT: Always use ServiceLink when attempting to diagnose problems with the automated gear shift (AGS) transmission.

In most cases, the J1587 fault code is the starting point for the troubleshooting procedures. See Subject 300 for a list of fault codes and the location of troubleshooting procedures for each code.

Use the electrical pre-test instructions given in

Table 1 as a baseline for troubleshooting when there is no de®nite problem, the malfunction is erratic or intermittent, or as an informational step to determine the general health of the electrical system. To record your ®ndings, a result sheet is provided at the end of this subject. For locations of serial numbers, see

Fig. 1 and Fig. 2.

Electrical Pre-Test Instructions

Before starting any procedures, use ServiceLink to depressurize the AGS hydraulic system. For detailed procedures, see Subject 160.

Electrical Pre-Test

Procedure	Result			Action
Make sure that the selector switch on the	The current gear indicator does not		Troubleshoot the current gear
SmartShift lever is set to N. Turn on the	power up normally. No fault codes		indicator. See Table 4.
ignition switch to power up the	display.
transmission.
NOTE: If the hydraulic pump starts up with
	The current gear indicator goes		Turn off the ignition switch and go to
its characteristic humming noise, this
	through its normal power-up		the next row in the table.
means the main power cables are OK (see
	sequence, ending by displaying "N."
the steps below to check the X3
connector).
With the ignition switch off, check the	Voltage is less than 11 or greater		Charge or replace the battery. For
voltage at the battery.	than 13 volts.		battery charging procedures, see
			Section 54.12, Subject 150.
	Voltage is between 11 and 13 volts.		Go to the next row in the table.
Remove the X3 (electric motor 2-pin)
connector from the transmission control unit
(TCU). Check the electric motor power
circuit.
	2			1
	06/01/2004	X3		f544485
Check for voltage between pin 1 (power	Voltage drops more than 0.2 volts		Repair or replace the wiring as
circuit 232) of the X3 connector and the	from the voltage measured at the		needed. See Section 54.06, Subject
battery ground terminal.	battery.		100.
	Voltage is within 0.2 volts of the		Go to the next row in the table.
	voltage measured at the battery.

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Troubleshooting Without Fault Codes

Electrical Pre-Test

Procedure

Result

Action

Check for resistance between pin 2

Resistance is greater than 0.3 ohms.

Repair or replace the wiring as

(ground) of the X3 connector and the

needed. See Section 54.06, Subject

battery ground terminal.

100.

Resistance is 0.3 ohms or less.

Go to the next row in the table.

Remove the X1 (vehicle 21-pin) connector

from the transmission control unit (TCU).

Check the battery power circuit.

	21						18		15	12			9	6	3
						20	17		14	11			8	5	2
						19	16		13	10			7	4	1
	07/16/2004									X1									f544483b
Check for voltage from pins 12 and 15	Voltage drops more than 0.2 volts											Repair or replace the wiring as
(battery power circuit 232D) of the X1	from the voltage measured at the											needed. See Section 54.06, Subject
connector to the battery ground terminal.	battery.											100.
	Voltage is within 0.2 volts of the											Go to the next row in the table.
	voltage measured at the battery.
Turn on the ignition switch. Check the
ignition power circuit.
									15	12				6	3
	21						18						9
						20	17		14	11			8	5	2
						19	16		13	10			7	4	1
	07/16/2004									X1									f544483c
Check for voltage from pin 9 (ignition power	Voltage drops more than 0.2 volts											Repair or replace the wiring as
circuit 232E) of the X1 connector to the	from the voltage measured at the											needed. See Section 54.06, Subject
battery ground terminal.	battery.											100.
	Voltage is within 0.2 volts of the											Go to the next row in the table.
	voltage measured at the battery.

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Transmissions

Troubleshooting Without Fault Codes

Electrical Pre-Test

Procedure

Result

Action

Turn off the ignition switch. Check the

ignition ground circuit.

		21	18	15	12	9	6	3
		20	17	14	11	8	5	2
		19	16	13	10	7	4	1
		07/21/2004			X1			f544483d
	With the ignition switch off, check for	Resistance is greater than 0.3 ohms.			Repair or replace the wiring as
	resistance between pins 18 and 21				needed. See Section 54.06, Subject
	(ground) of the X1 connector and the				100.
	battery ground terminal.	Resistance is 0.3 ohms or less.			Go to the next row in the table.
	Turn off the ignition switch. Check the
	J1587 wiring.
		21	18	15	12	9	6	3
		20	17	14	11	8	5	2
		19	16	13	10	7	4	1
		07/21/2004			X1			f544483e
	Check for DC voltage from pins 11 and 14	Voltage is less than 1 or more than 4			Troubleshoot the J1587 datalink.
	(J1587 datalink) of the X1 connector to the	volt(s) for DC (less than 1 or more
	battery ground terminal.	than 3 for AC).
	NOTE: If the meter cannot display the	Voltage is between 1 and 4 volts for			Go to the next row in the table.
	rapidly shifting DC voltage, measure AC
		DC (1±3 volts AC).
	voltage instead.
	Turn off the ignition switch. Check the
	J1939 wiring.
		21	18	15	12	9	6	3
		20	17	14	11	8	5	2
		19	16	13	10	7	4	1
		07/16/2004			X1			f544483a

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Troubleshooting Without Fault Codes

Electrical Pre-Test

	Procedure	Result	Action
	With the ignition switch off, remove the X1	Resistance is less than 55 or greater	Troubleshoot the J1939 datalink. See
	connector from the TCU and check for	than 65 ohms.	Freightliner Service Bulletin 54-133.
	resistance between pins 7 and 13 (J1939
		Resistance is between 55 and 65	The vehicle has passed the electrical
	datalink).
		ohms.	pre-test. Troubleshoot active fault
			codes, if any.
		Table 1, Electrical Pre-Test

NOTE: To see the identi®cation plate on the TCU it may be necessary to remove the splash guard.

				0 0 3	2 0 0 4
4 7 7		0 0 1	0 0 6	0
A	9 7 0		2 6 0	0 3		5 9	000525
				3			4

5

1

2

10/05/2006

f261384

NOTE: The TCU and X-Y Actuator each have their own WABCO identi®cation plate (arrows) with unique serial numbers.

1. TCU (Transmission	4.	Serial Number
Control Unit)	5.	X-Y Actuator

2.Splash Guard

3.WABCO Identi®cation Plate

Fig. 1, Serial Numbers for TCU and X-Y Actuator

	DaimlerChrysler		1
	Bez: G 60−6		2
	IdNr 715053 123456
	Code C07−00036−031
	M−C
	Var. 041962
		DaimlerChrysler
		Bez: G 60−6
		IdNr 715053 123456
		Code C07−00036−031
		M−C
		Var. 041962
10/05/2006			f261383
1.	Transmission	2.	Serial Number
	Identi®cation Plate

Fig. 2, Transmission Serial Number

Troubleshooting Tables, No

Fault Codes

In a few cases there will be a de®nite problem and no J1587 fault code will be sent.

•If the engine will not crank and there are no transmission fault codes, see Table 2.

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Transmissions

Transmission Range Faults (PID 162 and 163)

Transmission Range Faults

Transmission Range-Selected

Faults (PID 162)

There is one transmission range-selected fault covered in these procedures.

•For PID 162, FMI 02, see Table 1 for procedures.

Transmission Range-Attained

Faults (PID 163)

There is one transmission range-attained fault covered in these procedures.

•For PID 163, FMI 02, see Table 2 for procedures.

PID 162, FMI 02ÐThe Transmission Is Not Properly Calibrated

Failure Reason:

•The gears are caught in an intermediate position.

•The transmission software does not allow shifting.

Problem	Procedure	Result	Action
There are other	Check for other MID 130 fault codes.	Other fault codes	Troubleshoot the
active transmission		are active.	other active fault
faults.			codes.
		No other fault	Go to the next step
		codes are active.	in the table.
The transmission	Complete a learning procedure using either ServiceLink or	The fault is no	No further action is
needs to be	the SmartShift control.	longer active.	needed.
recalibrated.	To complete a learning procedure using the SmartShift
	control:
	1. Ensure that the parking brake is set.
	2. With the ignition turned off, pull and hold the SmartShift
	control toward steering wheel.
	NOTE: The SmartShift control must be kept in this position
	until the gear display clears at the end of the procedure.
	3. Turn on the ignition. The normal warm up procedure will
	initiate and an 'X' will display on the current gear indicator.
		The fault is still	Contact
	Your transmission may be heard shifting.
		active.	Freightliner
	4. Wait until the current gear indicator displays an 'N'
			Technical Service
	(about 30 seconds) and an audible alert sounds. Start the		Support.
	engine within 10 seconds of the audible alert.
	5. The engine will raise a few rpm, then fall back to idle,
	and an audible alert will sound. Turn off the engine within
	10 seconds of audible alert. When the gear display clears,
	this procedure is complete.
	NOTE: If during this procedure an 'SM' or 'X' (after the
	warm up procedure) appears in the gear display, stop, turn
	off the ignition, and wait for the gear display to go dark.
	Then start over. This may need to be repeated several
	times.

Table 1, The Transmission Is Not Properly Calibrated

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Transmission Range Faults (PID 162 and 163)

PID 163, FMI 02ÐThe Gears Do Not Shift Properly

Failure Reason:

• There is a defect in the TCU.

• There is a defect in the speed sensor.

• There is a defect in the actuator.

• The transmission software is not properly programmed.

• The datalink does not recognize the transmission type.

Problem	Procedure	Result	Action
There are other	Check for other MID 130 fault codes.	Other fault codes are	Troubleshoot the other
active transmission		active.	active fault codes.
faults.
		No other fault codes are	Go to the next step in the
		active.	table.
There is a	Using the ServiceLink diagnostics template,	The x-y actuator	No further action is needed.
transmission	view the different gear positions, check that	responds properly and
software problem.	the clutch opens and closes, and that the	the fault clears.
	x-y actuator moves from reverse, 1st, and
		The fault is still active.	Go to the next step in the
	2nd gears.
			table.
There is component	Do a visual inspection of the x-y actuator,	Damaged components	Contact Mercedes-Benz
damage in the	the hydraulic system, and the transmission	are found.	Transmissions Service
transmission.	shift system.		Support with the AGS
			codes and results of the
			electrical pre-test.
			NOTE: One hour of
			troubleshooting time is
			alloted for printing the AGS
			codes and completing the
			electrical pre-test.
			1. Using ServiceLink, print
			the AGS codes (130).
		No damaged	2. Complete the electrical
		components are found.
			pre-test result sheet in
			Subject 301.
			3. With the results, contact
			Mercedes-Benz
			Transmissions Service
			Support by fax
			(503.961.8435), email
			(MBTServiceSupport@
			Freightliner.com), or phone
			(503.745.4965 or
			503.745.4988).
	Table 2, The Gears Do Not Shift Properly

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Output Shaft Speed Sensor Faults (PID 191)

Output Shaft Speed Sensor

Faults (PID 191)

There are four output shaft speed sensor faults covered in these procedures. One troubleshooting procedure is used to correct FMI 02, 05, and 08. A separate procedure is used for FMI 14.

•For PID 191, FMI 02, 05, and 08 see Table 1 for procedures and pin identi®cation.

•For PID 191, FMI 14, see Table 2 for procedures.

PID 191, FMI 02, 05, 08ÐThe Output Shaft Speed Sensor Circuit Gives Invalid Data, Is Open, or Not Broadcasting a Signal

Failure Reason:

• The TCU has a hardware prob-

lem.

• The sensor is mounted too loose

(air gap too big).

1

4

7

10

13

• The sensor connectors are dam-

2

5

8

11 14

aged or bent.

• The wiring harness has had an

3

6

9

12

15

electrical failure.

X2

• Either one of the sensors or the

07/16/2004

f544484k

TCU has failed.

Procedure

Results

Action

Turn on the ignition switch and wait for

Fault code SID 254, FMI 12 is active.

Go to Subject 309 and troubleshoot

the current gear display to power up.

SID 254, FMI 12.

SID 254, FMI 12 is not active.

Go to the next row in the table.

Remove both output shaft speed

The fault clears after a test drive.

No further action needed.

sensors. Reinstall and tighten the sensor

The fault remains active.

Go to the next row in the table.

28 lbf´ft (38 N´m).

Turn off the ignition switch and wait for

The connector pins are damaged or

Repair or replace the damage.

the current gear display to power down.

bent.

Remove both sensor connectors and

There is no damage to either

Go to the next row in the table.

visually inspect the pins.

connector.

Check the upper sensor for continuity:

There is an open circuit.

Replace the transmission wiring

(1) X2 connector pin 1 to sensor pin 2;

harness (see Subject 180).

(2) X2 connector pin 15 to sensor pin 1;

The wiring is OK.

Go to the next row in the table.

(3) X2 connector pin 14 to sensor pin 4.

Check the lower sensor for continuity:

There is an open circuit.

Replace the transmission wiring

(1) X2 connector pin 1 to sensor pin 2;

harness (see Subject 180).

(2) X2 connector pin 15 to sensor pin 1;

The wiring is OK.

Go to the next row in the table.

(3) X2 connector pin 9 to sensor pin 3.

Check all four pins of each sensor

Voltage or continuity is found.

Replace the transmission wiring

connector for voltage and for continuity

harness (see Subject 180).

to ground.

There is zero voltage and no continuity.

Go to the next row in the table.

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Output Shaft Speed Sensor Faults (PID 191)

PID 191, FMI 02, 05, 08ÐThe Output Shaft Speed Sensor Circuit Gives Invalid Data, Is Open, or Not Broadcasting a Signal

Failure Reason:

•The TCU has a hardware problem.

•The sensor is mounted too loose

(air gap too big).

1

4

7

10

13

• The sensor connectors are dam-

2

5

8

11 14

aged or bent.

• The wiring harness has had an

3

6

9

12

15

electrical failure.

X2

• Either one of the sensors or the

07/16/2004

f544484k

TCU has failed.

Procedure

Results

Action

Using a sensor known to be good,

The fault becomes inactive.

No further action needed.

replace each sensor in turn (see

The fault is still active.

Contact Mercedes-Benz Transmissions

Subject 120 for procedures).

Service Support with the AGS codes

and results of the electrical pre-test.

NOTE: One hour of troubleshooting

time is alloted for printing the AGS

codes and completing the electrical

pre-test.

1. Using ServiceLink, print the AGS

codes (130).

2. Complete the electrical pre-test

result sheet in Subject 301.

3. With the results, contact Mercedes-

Benz Transmissions Service Support

by fax [phone]), email

(MBTServiceSupport@

Freightliner.com), or phone

(503.745.4965 or 503.745.4988).

Table 1, The Output Shaft Speed Sensor Circuit Gives Invalid Data, Is Open, or Not Broadcasting a Signal

PID 191, FMI 14ÐThe Output Shaft Speed Sensor Is Providing Invalid Data

Failure Reason

•The antilock brake system (ABS) is not broadcasting wheel speed data.

•There is a defective output shaft speed sensor.

Procedure	Result	Action
Check for other PID 191 fault codes.	Other PID 191 fault codes	Troubleshoot PID 191. See
	are active.	Table 1.
	No other PID 191 fault	Go to the next step in the
	codes are active.	table.

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Transmissions

Output Shaft Speed Sensor Faults (PID 191)

PID 191, FMI 14ÐThe Output Shaft Speed Sensor Is Providing Invalid Data

Failure Reason

•The antilock brake system (ABS) is not broadcasting wheel speed data.

•There is a defective output shaft speed sensor.

Procedure	Result	Action
Check for active fault codes in MID 136 (ABS).	Active MID 136 fault codes	Troubleshoot the ABS system
	are found.	(see the applicable section in
		Group 42).

Table 2, The Output Shaft Speed Sensor Is Providing Invalid Data

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	Speci®cations

For a schematic of the AGS transmission wiring behind the X2 (transmission) connector, see Fig. 1. For a schematic of the AGS transmission wiring behind the X1 (main vehicle) and X3 (electric motor) connectors, see drawing G06-49466.

For a list of special tools, see Table 1.

Input Shaft Speed			Output Shaft Speed Sensor			Output Shaft Speed Sensor
	Sensor			(9:00 position)		(11:00 position)
			3	2		S	2
			S	GND			GND
				+12V		+12V
2	1			1		1
13	11		9		14	15	1
			X2 Connector
7	3	2	6	10	5	4	12
2	1	2	1	2	1	2	1
Gear Position Sensor		Rail Position Sensor		Clutch Position Sensor		Fluid Level Sensor
	(Front)		(Rear)			(Pentosin)
02/01/2005						Circuit is closed when full
							f544529

Fig. 1, AGS Transmission Wiring, X2 Connector

Special Tools for AGS Transmission

Tool

Description

Manufacturer

Part Number

Accumulator Torque Adaptor

Kent-Moore

J-47291

f580381

Low-Pressure Hose Disconnect Tool

Kent-Moore

J-47202

f580379a

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Freightliner AMT3	and Mercedes-Benz Automated-Manual
26.03	Transmissions
Speci®cations

Special Tools for AGS Transmission

Tool

Description

Manufacturer

Part Number

High-Pressure Line Disconnect Tool

Kent-Moore

J-47201

f580379

Shift Finger Alignment Fork

Kent-Moore

J-47204

f580380

Shift Mechanism End Guide

Kent-Moore

J-47203

f580382

Table 1, Special Tools for AGS Transmission

For transmission installation torque values, see

Table 2.

Transmission Installation Torque Values

	Description	Size	Class	Torque: lbf´ft (N´m)
	Midship Bearing Bracket Capscrews	3/4±11	Ð	91 (123)
	Power Takeoff Unit (PTO) Mounting Capscrews	M10	10.9	43 (58)
	Transmission Fluid Drain Plug	M24	Ð	42	(57)
	Transmission Fluid Fill Plug	M24	Ð	42	(57)
	Transmission Mounting Bolts	M10 x 1.5	8.8	33 (45)
	U-Joint End Cap Bolts	3/8±24	Ð	50 (68)
		1/2±20	Ð	110	(149)

Table 2, Transmission Installation Torque Values

For AGS assembly torque values, see Table 3.

AGS Assembly Torque Values

Description	Size	Torque: lbf´ft (N´m)	Torque: lbf´in (N´cm)
Accumulator Hydraulic Fitting	M30	59 (80)	Ð
X-Y Actuator Mounting Capscrews	M8	17 (23)	Ð

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Business Class M2 Workshop Manual, Supplement 20, September 2011

Freightliner AMT3 and Mercedes-Benz Automated-Manual	26.03
Transmissions
	Speci®cations

AGS Assembly Torque Values

Description	Size	Torque: lbf´ft (N´m)	Torque: lbf´in (N´cm)
AGS Central Unit Mounting Capscrews	M8	17 (23)	Ð
Clutch Actuator Hydraulic Fittings	M30	37 (50)	Ð
Clutch Actuator Mounting Capscrews	M8	17 (23)	Ð
Pressure-Limiting Valve Adjusting Screw	M6	Ð	63±71 (700±800)
Reservoir Base Fasteners	M8	11 (15)	Ð
Reservoir Top Fasteners	M6	Ð	71 (800)
Rotational Speed (RPM) Sensors	Ð	28 (38)	Ð
Shift Rod Setscrew	M12	22 (30)	Ð
Transmission Control Unit (TCU) Mounting Screws	M8	Ð	44±53 (500±600)
TCU Splash Guard Mounting Capscrews	M8	17 (23)	Ð
Table 3, AGS Assembly Torque Values

For AGS transmission gear ratios, see Table 4.

AGS Transmission Gear Ratios

Model	Gear	Ratio
	1	9.201
	2	5.230
	3	3.145
MBT520-6DA
	4	2.034
	5	1.374
	6	1.000
	R	8.649
	1	6.700
	2	3.810
	3	2.290
MBT660-6OA
	4	1.480
	5	1.000
	6	0.730
	R	6.290

Table 4, AGS Transmission Gear Ratios

For a list of proprietary fault codes viewable on ServiceLink, see Table 5.

	AGS Proprietary Fault Codes (J1708)
Fault Code	Description
3000109	High voltage supply voltageÐexternal (connector X1/12 and X1/15)

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Freightliner AMT3	and Mercedes-Benz Automated-Manual
26.03	Transmissions
Speci®cations

	AGS Proprietary Fault Codes (J1708)
Fault Code	Description
3000113	High voltage ignition key lineÐexternal (connector X1/9)
3000209	Low voltage supply voltageÐexternal (connector X1/12 and X1/15)
3000213	Low voltage ignition key lineÐexternal (connector X1/9)
3001210	EEPROM parameter values errorÐinternal
3001510	Clutch displacement control module parameter errorÐinternal
3001781	Clutch calibration offset off limitÐinternal
3002009	Open load supply voltageÐexternal (connector X1/12 and X1/15)
3002016	Open load/Short circuit VCC temperature sensor circuit boardÐinternal
3002017	Open load/Short circuit VCC temperature sensor pumpÐinternal
3002116	Short circuit GND temperature sensor circuit boardÐinternal
3002117	Short circuit GND temperature sensor pumpÐinternal
3002214	Short circuit VCC peripherals supplyÐexternal (connector X2/15)
3003001	EBC1 message timeoutÐexternal (J1939)
3003101	EEC1 message timeoutÐexternal (J1939)
3003201	EEC2 message timeoutÐexternal (J1939)
3003301	EEC3 message timeoutÐexternal (J1939)
3003401	ERC1 message timeoutÐexternal (J1939)
3003501	Wheel speed information message timeoutÐexternal (J1939)
3003601	CruiseControl (VCU) message timeoutÐexternal (J1939)
3003701	CruiseControl (bulkhead) message timeoutÐexternal (J1939)
3003801	Engine con®guration message timeoutÐexternal (J1939)
3003901	Retarder con®guration message timeoutÐexternal (J1939)
3004001	Component identi®cation message timeoutÐexternal (J1939)
3004101	PTO information message timeoutÐexternal (J1939)
3006101	Incorrect engine dataÐexternal (J1939)
3006201	Timeout converted engine data for clutch module (low priority)Ðinternal
3006701	Incorrect retarder dataÐexternal (J1939)
3006801	Incorrect ABS dataÐexternal (J1939)
3006901	Incorrect internal dataÐinternal
3007001	Incorrect clutch module dataÐinternal
3007101	Incorrect automated gear shift module dataÐinternal
3007201	Incorrect internal dataÐinternal
3008881	Clutch overloadÐinternal
3009280	Plausibility error actual transmission gear ratioÐinternal
3009710	Test softwareÐinternal
3009810	Test electronicÐinternal

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Freightliner AMT3 and Mercedes-Benz Automated-Manual	26.03
Transmissions
	Speci®cations

	AGS Proprietary Fault Codes (J1708)
Fault Code	Description
3009910	Test bench mode activatedÐinternal
3010390	Automatic module: signal group cruise control / retarderÐinternal
3010690	Automatic module: signal output speedÐinternal
3010790	Automatic module: signal group MRÐinternal
3010890	Automatic module: signal group gear ratioÐinternal
3010990	Automatic module: learning values engineÐinternal
3011081	Plausibility error intended clutch position can not be reached within speci®ed timeÐinternal
3011090	Automatic module: learning values transmissionÐinternal
3011310	Clutch calibration data missing/errorÐinternal
3011410	Clutch parameter errorÐinternal
3011590	Automatic module: signal group shifting timeÐinternal
3011690	Automatic module: signal group ABSÐinternal
3011790	Automatic module: signal group pedal activationÐinternal
3011890	Automatic module: signal group leverÐinternal
3011990	Automatic module: error target systemÐinternal
3012014	Open load peripherals supplyÐexternal (connector X2/15)
3012019	Plausibility error valve relay V-V2 onÐinternal
3012035	Open load power stage solenoid valve (clutch open 1)Ðinternal
3012036	Open load power stage solenoid valve (clutch open 2)Ðinternal
3012037	Open load power stage solenoid valve (clutch close 1)Ðinternal
3012038	Open load power stage solenoid valve (clutch close 2)Ðinternal
3012050	Open load speed sensor transmission output (DZ1)Ðexternal (connector X2/14)
3012051	Open load speed sensor transmission inputÐexternal (connector X2/11)
3012052	Open load speed sensor transmission output (D3)Ðexternal (connector X2/9)
3012090	Automatic module: system identi®cation gearshift moduleÐinternal
3012114	Short circuit to GND peripherals supplyÐexternal (connector X2/15)
3012118	Plausibility error valve relay V-V1 offÐinternal
3012119	Plausibility error valve relay V-V2 offÐinternal
3012136	Short circuit GND power stage solenoid valve (clutch open 2)Ðinternal
3012138	Short circuit GND power stage solenoid valve (clutch close 2)Ðinternal
3012151	Short circuit GND speed sensor transmission inputÐexternal (connector X2/11
3012251	Short circuit VCC speed sensor transmission inputÐexternal (connector X2/11)
3012461	Hydraulic level too low externalÐexternal
3016201	Timeout converted engine data for clutch module (medium priority)Ðinternal
3016401	Timeout driving direction informationÐinternal
3016501	Timeout internal communication shift module to clutch module (medium priority)Ðinternal

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Freightliner AMT3	and Mercedes-Benz Automated-Manual
26.03	Transmissions
Speci®cations

	AGS Proprietary Fault Codes (J1708)
Fault Code	Description
3018681	Plausibility error clutch open request while inlet valves are closedÐinternal
3018781	Plausibility error clutch open request while outlet valves are closedÐinternal
3019480	Plausibility error driving directionÐinternal
3019621	SmartShift lever data invalidÐexternal (connector X1/8, X1/11, X1/14)
3019650	Tooth signal interruption speed sensor transmission output (DZ1)Ðexternal (connector X2/14)
3019651	Tooth signal interruption speed sensor transmission inputÐexternal (connector X2/11)
3019652	Tooth signal interruption speed sensor transmission output (D3)Ðexternal (connector X2/9)
3020110	High voltage distance sensor supplyÐinternal
3020111	Power supply high voltageÐexternal (connector X3/1)
3020210	Low voltage distance sensor supplyÐinternal
3020211	Power supply low voltageÐexternal (connector X3/1)
3021010	Flash checksum errorÐinternal
3021110	EEPROM calibration values errorÐinternal
3021610	Clutch displacement offset failureÐinternal
3022011	Supply voltage open loadÐexternal (connector X3/1)
3022012	Open load GND connectionÐexternal (connector X1/18 and X1/21)
3022015	Open load pressure sensor signalÐinternal
3022018	Plausibility error valve relay V-V1 onÐinternal
3022020	Open load GND pump motorÐexternal (connector X3/2)
3022030	Open load power stage solenoid valve (selection direction R)Ðinternal
3022031	Open load power stage solenoid valve (selection direction 5/6)Ðinternal
3022032	Open load power stage solenoid valveÐinternal
3022033	Open load power stage solenoid valve (gear direction 1,3,5)Ðinternal
3022034	Open load power stage solenoid valve (pressure regulation)Ðinternal
3022041	Open load distance sensor (gear)Ðinternal
3022042	Open load distance sensor (selection)Ðinternal
3022044	Open load distance sensor (clutch)Ðinternal
3022060	Open loop power stage pump motorÐinternal
3022115	Short circuit GND pressure sensor signalÐinternal
3022130	Short circuit GND power stage solenoid valve (selection direction R)Ðinternal
3022131	Short circuit GND power stage solenoid valve (selection direction 5/6)Ðinternal
3022132	Short circuit GND power stage solenoid valve (gear direction R,2,4,6)Ðinternal
3022133	Short circuit GND power stage solenoid valve (gear direction 1,3,5)Ðinternal
3022134	Short circuit GND power stage solenoid valve (pressure regulation)Ðinternal
3022135	Short circuit GND power stage solenoid valve (clutch open 1)Ðinternal
3022137	Short circuit GND power stage solenoid valve (clutch close 1)Ðinternal

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Freightliner AMT3 and Mercedes-Benz Automated-Manual	26.03
Transmissions
	Speci®cations

	AGS Proprietary Fault Codes (J1708)
Fault Code	Description
3022141	Short circuit GND distance sensor (gear)Ðinternal
3022142	Short circuit GND distance sensor (selection)Ðinternal
3022144	Short circuit GND distance sensor (clutch)Ðinternal
3022160	Short circuit GND power stage pump motorÐinternal
3022215	Short circuit VCC pressure sensor signalÐinternal
3022241	Short circuit VCC distance sensor (gear)Ðinternal
3022242	Short circuit VCC distance sensor (selection)Ðinternal
3022244	Short circuit VCC distance sensor (clutch)Ðinternal
3022317	Over temperature power stage pump motorÐinternal
3022590	Automatic module: no signal vehicle speedÐinternal
3022690	Automatic module: signal group MR (high priority)Ðinternal
3022790	Automatic module: signal group gear ratio (high priority)Ðinternal
3022890	Automatic module: learning values engine (high priority)Ðinternal
3022990	Automatic module: learning values transmission (high priority)Ðinternal
3024341	Erratic distance sensor (gear)Ðinternal
3024342	Erratic distance sensor (selection)Ðinternal
3024344	Erratic distance sensor (clutch)Ðinternal
3024441	Wrong coil resistance value distance sensor (gear)Ðinternal
3024442	Incorrect coil resistance value distance sensor (selection)Ðinternal
3024444	Incorrect coil resistance value distance sensor (clutch)Ðinternal
3024610	Timeout displacement sensor valueÐinternal
3026001	CAN bus offÐexternal (connector X1/13 and X1/7)
3026301	Timeout converted engine data for clutch module (high priority)Ðinternal
3026501	Timeout internal communication shift module to clutch module (high priority)Ðinternal
3027401	No J1939 communicationÐinternal / external (connector X1/13 and X1/7)
3027501	Timeout internal communication shift module to clutch module (high priority)Ðinternal
3028581	Clutch displacement control failureÐinternal
3029180	No calculation of redundant transmission output speedÐinternal
3029380	Incorrect transmission typeÐinternal
3029580	Plausibility error pressure build upÐinternal
	Table 5, AGS Proprietary Fault Codes (J1708)

For a list of learning procedure errors, see Table 6.

	Learning Procedure Errors
Error	Description
56	Offset of clutch position out of range

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Freightliner AMT3	and Mercedes-Benz Automated-Manual
26.03	Transmissions
Speci®cations

	Learning Procedure Errors
Error	Description
57	Offset of pressure modulation valve out of range
58	Gear position "neutral" out of range
61	Low gear position out of range
62	High gear position out of range
63	Low select position out of range
66	High select position out of range
68	Valve or sensor failure
69	Vehicle is moving
70	Low voltage or high voltage
71	Clutch open/closed
72	Stalk lever position changed during learning procedure
73	Type of gear box invalid
74	Park brake not activated
76	Engine is running
77	Engine torque invalid or out of range
78	Engine was not started in time
80	Accelerator pedal not idle
82	Countershaft speed not zero
	Table 6, Learning Procedure Errors

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Business Class M2 Workshop Manual, Supplement 20, September 2011

Mercedes-Benz Manual Transmission

26.04

General Information

The Mercedes-Benz transmission (MBT) is offered in two 6-speed models:

•MBT520S-6D, direct drive, 520 lb´ft torque rating

•MBT660S-6O, overdrive, 660 lb´ft torque rating

The gear case holds 9.5 quarts (9.0 liters) of oil. MobilTrans SHC® DC is the approved oil.

Both models are fully synchronized for reduced shifting effort. Equipped with six forward speeds and one reverse speed, both models show a particularly large overall ratio between low and top gear. See Speci®- cations, 400 for gear ratios for each model.

To reduce ¯uid change intervals and to increase bearing life, MBT transmissions are designed with "clean" bearings. These bearings have covers on both sides. They cannot be damaged by the wear particles that accumulate in the ¯uid. The geometry of the gear teeth has been optimized to provide lownoise operation and extended gear life.

The bell housing has been designed around standard SAE bolt patterns. SAE2 is standard on both MBT660S-6O and MBT520S-6D models.

Other features of the MBT transmissions include:

•Light metal gear cases with integrated bell housings;

•Low installation height (the shift interface is positioned laterally);

•Double synchronization from 1st gear to 4th gear;

•Electronic vehicle speed sensor;

•Longer oil change intervals;

•Full range of PTO units available.

Each model requires a hydraulic clutch system. No clutches with manual control can be installed for use on MBT transmissions. With the hydraulic system installed, the clutch linkage is self-adjusting.

The hydraulic clutch system consists of the following parts:

•Hydraulic ¯uid reservoir;

•Clutch pedal unit;

•Master cylinder;

General Information

•Slave cylinder;

•Hydraulic lines connecting the various parts of the system.

The MBT transmission removal and installation procedures have been moved to Subject 100 from their previous location in Section 26.00.

The teardown procedures included in this section also apply to the AGS automated transmission, with slight changes which are indicated at appropriate places in the procedures. If it is necessary to tear down the AGS transmission, be sure to remove the AGS assembly before proceeding. See Sec-

tion 26.03, Subject 200 for procedures.

On all transmissions, disassembly of the transmission main shaft is not recommended except when it is necessary to check for synchronizer wear. Disassembly of the countershaft is not recommended in any case.

It is important to check main shaft end play if either gear case half, the main shaft bearings, or the input shaft is replaced. For detailed procedures, see Subject 250.

To prevent premature tool wear, use extreme pressure lubricant such as Kent-Moore J 23444-A or equivalent on tool threads and at all friction and contact points.

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Mercedes-Benz Manual Transmission

26.04

Transmission Removal and Installation

Removal

1.Park the vehicle on a level surface. Shut down the engine, set the parking brake, and chock the rear tires.

2.Drain the transmission ¯uid. SeeFig. 1 for the location of the drain plug.

1

3	2	f261102
05/22/2001

NOTE: The transmission is shown from the left-hand side.

1.	Transmission	3. Drain Plug
2.	Fill Plug

Fig. 1, Transmission Drain and Fill Plugs

3.Disconnect the driveshaft from the transmission.

3.1Support the midship bearing.

3.2Remove the bolts from the U-joint end caps and slide the front of the driveshaft out of the transmission output yoke. See

Fig. 2.

3.3Remove the midship bearing bracket. See

Fig. 3.

3.4Support the disconnected driveshaft and chain it out of the way. See Fig. 4.

4.Remove the shift lever from the transmission.

4.1Before removing the shift lever, place the transmission in high gear.

4.2Remove the four screws from the retaining ring around the shift lever boot. See

Fig. 5. Remove the ring and the boot.

4.3Remove the head of the shift lever from the transmission. See Fig. 6. For ease of

		1
		2	3
06/05/2001			f261005
1.	Transmission	3.	Driveshaft
2.	Output Yoke

Fig. 2, Output Yoke

	2
	3
			3
			1
01/28/99			f261006
1.	Midship Bracket	3.	Driveshaft
2.	Mounting Bolt

Fig. 3, Midship Bearing Bracket

installation, mark the head of the shift lever and the attachment point on the transmission with a paint pen.

5.Remove the fuel lines and the fuel line standoff bracket from the transmission. See Fig. 7.

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26.04 Mercedes-Benz Manual Transmission

Transmission Removal and Installation

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f261007

Fig. 4, Supporting the Driveshaft

07/14/94

f260074a

Fig. 5, Shift Lever and Boot

	1
		1
	2
	3
	4
06/06/2001		f261108
1.	Shift Lever
2.	Shift Lever Mounting Bolt
3.	Thick Washer
4.	Head of Shift Lever

Fig. 6, Shift Lever Connection

6.Disconnect the electrical connectors for the reverse gear switch and the optional starter lock switch (if installed). Mark with a paint pen for ease of installation.

WARNING

Do not press down on the clutch pedal after removing the slave cylinder. Hydraulic brake ¯uid may squirt out, causing personal injury and damage to the vehicle.

7.Remove the bolts that attach the clutch slave cylinder to the mounting ¯ange on the gear case. Move the slave cylinder out of the way. See

Fig. 8.

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Mercedes-Benz Manual Transmission

26.04

Transmission Removal and Installation

			3
			2
	1
06/05/2001			f261009
1.	Speedometer Sensor	3.	Standoff Bracket
2.	Fuel Line

Fig. 7, Fuel Line Standoff Bracket and Speedometer

Sensor

		1	2
			3
05/24/2001			f261107
1.	M8 Bolts	3.	Slave Cylinder
2.	Bleed Valve

Fig. 8, Hydraulic Clutch Slave Cylinder

8.Bend back the nut retainers and remove the power take-off unit (PTO), if installed. See Fig. 9.

9.If the vehicle is equipped with optional dual fuel tanks, remove the fuel cross-over line and its support between the tanks.

10.Disconnect the electrical cable from the speedometer sensor and mark it with a paint pen for ease of installation. See Fig. 7.

11.Remove the battery cable bracket(s) around the transmission and move the battery cables out of the way. See Fig. 10.

05/14/2001

f261105

Bend back the nut retainer (arrow).

Fig. 9, Power Take-Off Unit (PTO) Nut Retainers

				3
	05/14/2001		1	2
				f261106
	1.	Battery Cable
	2.	Battery Cable Clamp
	3.	Battery Cable Bracket

Fig. 10, Battery Cable Routing

12.Remove the exhaust clamp at the exhaust elbow. For ease of transmission removal and installation, move the exhaust pipe to the side and out of the way.

13.Support the transmission with a jack. See

Fig. 11.

13.1Position a transmission jack under the transmission and raise its support plates against the base of the transmission.

13.2Adjust the support plates to cradle the transmission.

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26.04 Mercedes-Benz Manual Transmission

Transmission Removal and Installation

	1
2			3
03/01/99			f261014
1.	Transmission	3.	Jack
2.	Support Plate

Fig. 11, Supporting the Transmission

13.3Using a chain, secure the transmission to the jack.

14.Remove the 16-mm transmission mounting capscrews that attach the timing case to the bell housing. See Fig. 12.

14.1Remove the eleven transmission mounting capscrews.

14.2After removing the transmission, insert the capscrews into the holes in the timing case, rather than in the bell housing.

CAUTION

Do not allow the rear of the transmission to drop, and do not allow the transmission to hang unsupported. Keep the ¯ange of the bell housing parallel (all the way around) to the ¯ange of the timing case, until the input shaft is clear of the

01/29/99

f261011

Fig. 12, Capscrews Left in the Timing Case

¯ywheel. Taking these precautions will prevent damage to the input shaft, ¯ywheel, and clutch.

15.After making sure that the transmission is ®rmly secured and well supported, remove the transmission from the vehicle. See Fig. 13.

01/29/99

f261013

Make sure that the transmission is ®rmly secured and well supported.

Fig. 13, Transmission Ready To Remove

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Business Class M2 Workshop Manual, Supplement 8, September 2005

Mercedes-Benz Manual Transmission

26.04

Transmission Removal and Installation

15.1Pull the transmission and jack straight back until the transmission input shaft is clear of the clutch.

15.2Turn the left-hand front wheel to allow room for the transmission to pass. If necessary, lower the jack supporting the transmission. It might also be necessary to jack up the truck to get enough clearance to allow the transmission to pass.

IMPORTANT: Watch closely the clearance between the bell housing and the leaf spring.

15.3Pull the transmission out through the space behind the front wheel.

Installation

IMPORTANT: Before installing the transmission, make sure that the rear tires are chocked and that the transmission is securely chained to the support plates on the transmission jack.

1.Install the transmission. See Fig. 14.

1.1Align the jack and the transmission behind the engine.

1.2Raise the transmission and adjust the angle of the jack until the bell housing and the timing case ¯ange are parallel.

1.3Push the transmission and jack straight forward.

NOTE: While installing the transmission mounting capscrews, also install the battery cable bracket(s), as removed.

1.4Install the eleven M10 transmission mounting capscrews. Use a crossover pattern. Do a ®nal tightening of the capscrews to 33 lbf´ft (45 N´m).

1.5Remove the chain around the transmission and the jack; then remove the jack.

2.Install the exhaust clamp at the exhaust elbow, as removed.

3.If the vehicle is equipped with the optional dual fuel tanks, install the fuel cross-over line and its support between the tanks. Tighten the clamps

		2	3	4
				5
1
				6	7
				8
07/25/2005	12	11	10	9
				f261103a

NOTE: The transmission is shown from the left-hand side.

1.Transmission Mounting Capscrews

2.Reverse Gear Switch

3.Shift Lever Mounting Bolt

4.Starter Lock Switch

5.Nameplate

6.Output Yoke Pressure Plate Mounting Capscrew

7.U-Joint End Cap Bolts

8.Speedometer Sensor Lock

9.Transmission Fluid Fill Plug

10.Transmission Fluid Drain Plug

11.PTO Mounting Capscrews

12.Clutch Slave Cylinder Mounting Bolts

Fig. 14, Transmission Fasteners

40 lbf´ft (54 N´m) and the mounting bolts 95 lbf´ft (129 N´m).

4.If removed, coat the mating surface of the PTO cover with Loctite® 509 or equivalent sealing compound. Install the PTO cover on the transmission. Tighten the M10 hardened mounting capscrews 43 lbf´ft (58 N´m). Lock the nut retainers in place.

5.Connect the driveshaft.

5.1Slide the front of the driveshaft into the transmission output yoke.

5.2Install the U-joint end caps on the output yoke. Tighten the bolt heads 50 lbf´ft (68 N´m) for 3/8-inch end cap bolts and 110 lbf´ft (149 N´m) for 1/2-inch end cap bolts.

5.3Install the midship bearing bracket, as removed. Tighten the nuts 95 lbf´ft (129 N´m).

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26.04 Mercedes-Benz Manual Transmission

Transmission Removal and Installation

6.Install the fuel line standoff bracket and connect the fuel lines to the bracket.

7.Connect the electrical connectors. Connect the electrical cable to the speedometer sensor. Connect the electrical connector(s) on the shift lever.

8.Install the shift lever.

8.1Fit the shift lever over the cone of the transmission tower.

10/05/94	A	B	f260006b
A. Full		B. Low

8.2Coat the hardened M10 x 20 shift lever mounting bolt with Loctite 242 or equivalent thread-locking compound.

8.3Insert the M10 bolt and a thick washer into the hole in the shift lever. See Fig. 6. Use the markings made during removal to install the shift lever in the correct orientation, so as to avoid cab ¯oor interference.

IMPORTANT: Don't forget to install the washer. Without the washer, the shift lever may loosen. The driver could lose control of the vehicle.

8.4Tighten the M10 bolt 50 lbf´ft (68 N´m).

8.5Work the shift lever around to make sure it shifts comfortably in all gears.

8.6Install the rubber boot and the metal retaining ring. Install the four screws and tighten against the cab ¯oor 28 lbf´ft (38 N´m). SeeFig. 5.

9.Fasten the clutch slave cylinder to the mounting ¯ange on the gear case and tighten the four M8 slave cylinder mounting bolts 15 lbf´ft (20 N´m).

10.If necessary, bleed the hydraulic clutch system. See Section 25.02, Subject 140 for detailed instructions.

11.Clean the transmission drain plug and install it in the gear case, along with a new aluminum gasket. Tighten the drain plug 42 lbf´ft (57 N´m).

12.Add Mobiltrans SHC® DC until the transmission ¯uid is level with the lower edge of the ®ll opening. See Fig. 1 for the location of the ®ll plug and Fig. 15 for checking the correct level. About 9.5 quarts (9.0 liters) is needed.

13.Clean the transmission ®ll plug and install it in the gear case, along with a new aluminum gasket. Tighten the ®ll plug 42 lbf´ft (57 N´m).

Fig. 15, Transmission Fluid Level Checking

14. Remove the chocks from the rear tires.

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Mercedes-Benz Manual Transmission

26.04

Shift Mechanism Removal and Installation

NOTE: These procedures are for the manual transmission with shift lever only. For the automated AGS transmission, see Sec-

tion 26.03, Subject 200.

Removal

1.Remove the transmission. For detailed procedures, see Subject 100.

2.Secure the transmission on a wooden pallet, or other device to keep it from moving.

3.Make sure the transmission is in neutral.

4.Remove the four capscrews that attach the shift rod housing to the ¯ange on the front gear case. See Fig. 1.

	1
	2
03/01/2005		3	f261178
1.	Front Gear Case
2.	Shift Rod Housing Capscrew
3.	Shift Rod Housing

Fig. 1, Shift Mechanism

5.Remove the shift rod from the front gear case.

5.1From the right-hand side of the transmission, remove the setscrew that holds the end of the shift rod. Discard the old setscrew.

5.2Remove and discard the shift rod cover from the right-hand side of the gear case.

5.3Pull the shift rod all the way out of the gear case.

Installation

NOTE: See the installation procedure in Section 26.03, Subject 200 for more information on the proper alignment of the shift ®nger in the shift rod.

1.Make sure that the indent in the shift rod end (shown by the arrow in Fig. 2) is facing aft for proper engagement with the setscrew.

2.Install the shift rod in the front gear case.

2.1Insert the shift rod into the front gear case.

2.2Turn the shift rod until the dimple is at the 9 o'clock position.

3.Install the shift rod housing on the front gear case.

3.1Push the housing in until the indent in the rod end is showing in the setscrew hole.

3.2Coat the threads of a new setscrew with Loctite® 242 or equivalent thread-locking compound. Insert the new setscrew and tighten it 30 lbf´ft (40 N´m). SeeFig. 3.

3.3Install a new shift rod cover in the shift cover housing.

3.4Position the shift rod housing over the ¯ange in the front gear case. Coat the mating surfaces with a bead of Loctite 509 or equivalent sealing compound.

3.5Install the four capscrews that attach the shift rod housing to the front gear case. Coat the threads of the two lower capscrews with Loctite 242 or equivalent thread-locking compound. Tighten all four capscrews 18 lbf´ft (25 N´m).

4.Install the transmission. For detailed procedures, see Subject 100.

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42.00	Meritor WABCO Pneumatic Antilock Braking System
	(ABS)

Testing

6.Turn the ignition switch off.

7.If the voltage at the ECU is not within the speci- ®ed range, check the battery voltage and test the wiring to the ECU and to ground.

8.Connect the X1 connector to the ECU and remove the chocks from the tires.

ABS Pneumatic System Test

To check for air leaks in the ABS pneumatic system, listen for the sound of escaping air at each valve. To con®rm a slow air leak, apply a soap-and-water solution to air line ®ttings and watch for bubbles.

Wheel Speed Sensor Tests

Wheel Speed Sensor and Circuit

Resistance

To check the resistance in a wheel speed sensor circuit, perform the following test:

1.Park the vehicle on a level surface, set the parking brake, and shut down the engine. Chock the rear tires.

2.Disconnect the sensor cable connector from the ABS ECU. See Table 1.

ABS/ATC Circuit Pin and Wire Numbers

	Pin	Pin	Wire	Circuit Description
	Connector	Number	Number
		1	376C	ECU Ignition Supply
		2	376C	ECU #2 Positive 12 Volt Supply
		3	376T	Wheel Spin Light and ATC Switch
		4	1587+	J1587+
	X1	5	376R	Retarder Interrupt Signal
		6	1922-/1939-	J1922±/1939±
	Gray
		7	1922+/1939+	J1922+/1939+
		9	1587	J1587±
		10	376L	ABS Light
		11	XGRD	ECU Ground
		12	XGRD	ECU Ground
		1	Ð	Not used
		2	378LFI	Left Front Modulator Valve, In
		3	378RF0	Right Front Modulator Valve, Out
		4	378RFI	Right Front Modulator Valve, In
		5	377RF+	Right Front Sensor, High
	X2
		6	377RF±	Right Front Sensor, Low
	Black	7	377LF±	Left Front Sensor, Low
		8	377LF+	Left Front Sensor, High
		9	378RF±	Right Front Modulator Valve, Ground
		10	378LF0	Left Front Modulator Valve, Out
		11	378LF±	Left Front Modulator Valve, Ground
		12	Ð	Not used

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Business Class M2 Workshop Manual, Supplement 0, January 2002

Meritor WABCO Pneumatic Antilock Braking System	42.00
(ABS)
	Testing

ABS/ATC Circuit Pin and Wire Numbers

Pin		Pin	Wire	Circuit Description
Connector		Number	Number
		1	377LR+	Left Rear Sensor, High
		2	377LR±	Left Rear Sensor, Low
		3	377RR+	Right Rear Sensor, High
		4	377RR±	Right Rear Sensor, Low
		5	378T+	ATC Valve, High
X3
		6	378T±	ATC Valve, Low
Green		7	378RR0	Right Rear Modulator Valve, Out
		8	378RR±	Right Rear Modulator Valve, Ground
		9	378RRI	Right Rear Modulator Valve, In
		10	378LR0	Left Rear Modulator Valve, Out
		11	378LR±	Left Rear Modulator Valve, Ground
		12	378LRI	Left Rear Modulator Valve, In
	Table 1, ABS/ATC Circuit Pin and Wire Numbers

3.Connect ohmmeter probes to the sensor connector terminals and read the resistance.

•If the resistance is 900 to 2000 ohms, the cable and the sensor circuit are good. Proceed to the "Wheel Speed Sensor Voltage" test.

•If the resistance is less than 900 ohms or greater than 2000 ohms, perform the next test, "Wheel Speed Sensor Resistance."

Wheel Speed Sensor Resistance

To check the resistance in a wheel speed sensor, perform the following test:

1.Park the vehicle on a level surface, set the parking brake, and shut down the engine. Chock the rear tires.

2.Disconnect the wheel sensor cable from the chassis harness.

3.Connect ohmmeter probes to the pins on the sensor and read the resistance.

•If the resistance reading is 900 to 2000 ohms but the resistance noted in the previous test, "Wheel Speed Sensor and Circuit Resistance" was not, repair or replace the chassis harness wiring.

•If the resistance is less than 900 ohms or greater than 2000 ohms, clean the terminals and check the resistance again.

•If the resistance reading is still not correct, replace the sensor. See Subject 110 for instructions.

4.Install the connectors and remove the chocks from the tires.

Wheel Speed Sensor Voltage

NOTE: PC diagnostics can be used for this test to compare speed signal output of all sensors. A problem will be indicated by low or erratic output.

To check the voltage output of a wheel speed sensor:

1.Park the vehicle on a level surface, set the parking brake, and shut down the engine.

2.Chock the tires of the axle not being tested. Raise the vehicle and put jack stands under the axle so the wheels can rotate.

3.Disconnect the applicable connector from the ABS ECU for the sensor being tested. See

Table 1.

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