When repair work is carried out on the gearbox the following work sequence/instructions should be used.
Please take time to read the whole instruction before making any repairs on the gearbox.
The numbers in the table specify the work order for the choosen work sequence and the characters describe the different parts of a work sequence.
Work sequence | A | B | C | D | E | F | G | H |
Replacement of the ECU | 1 | 2 | 3 | 4 | - | 5 | 6 | 7 |
Removal/refitting of the ECU | 1 | 2 | 3 | 4 | - | - | - | - |
Replacement of the clutch thrust bearing | 1 | 2 | 3 | 4 | - | 5 | - | - |
Checking the oil level of the control actuator | 1 | 2 | 3 | - | - | - | - | - |
Draining the oil from the control actuator | 1 | 2 | 3 | 4 | - | - | - | - |
Replacement of a control actuator position sensor | - | 1 | - | - | - | - | 2 | - |
Replacement of the hydralic unit | 1 | 2 | 3 | 4 | - | 5 | 6 | 7 |
Removal/refitting of the hydralic unit | 1 | 2 | 3 | 4 | - | - | - | - |
Replacement of the electric pump unit | 1 | 2 | 3 | 4 | - | - | - | 5 |
Removal/refitting of the electric pump unit | 1 | 2 | 3 | 4 | - | - | - | - |
Replacement of the control actuator | 1 | 2 | 3 | 4 | - | 5 | 6 | 7 |
Removal/refitting of the control actuator | 1 | 2 | 3 | 4 | - | 5 | 6 | - |
Replacement of an electrovalve or the pressure sensor | 1 | 2 | 3 | 4 | - | - | - | - |
Replacement of the reservoir of the control actuator or the accumulator | 1 | 2 | 3 | 4 | - | - | - | - |
Replacement of the electric motor of the electric pump unit | 1 | 2 | 3 | 4 | - | - | - | 5 |
Removal/refitting of the electric motor of the electric pump unit | 1 | 2 | 3 | 4 | - | - | - | - |
Replacement of the clutch mechanism or clutch plate | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 |
Removal/refitting of the clutch mechanism or clutch plate | 1 | 2 | 3 | 4 | - | 5 | - | - |
Replacing the gearbox | - | 1 | - | - | - | 2 | 3 | 4 |
Removing/refitting of the gearbox | - | 1 | - | - | - | 2 | 3 | - |
Replacement of the gear selector | - | 1 | - | - | - | - | - | 2 |
Replacement of the paddles at the steering wheel | - | 1 | - | - | - | - | - | 2 |
Summary of the work sequences:
A | Depressurize the hydraulic circuit. |
B | Mechanical work. |
C | Pressurize the hydraulic circuit. |
D | Bleeding of the hydraulic circuit. |
E | Reinitialisation of the auto-programming values. |
F | Programming of the clutch biting point |
G | Programming of the gearbox grid |
H | Clear counters. |
Explanation of the work sequences.
Depressurize the hydraulic circuit.
Note:
During the function, the ignition must not be switched off.
Test prerequisites:
Ignition on, engine off.
Gear in neutral.
All electrical loads should be switched off.
Battery voltage above 12 Volts.
Procedure:
Start the function.
The system is now depressurized.
A dialog box presents: operation succeeded/ failed.
If the function fails, check test prerequisites and repair possible fault codes.
Exit the function.
Mechanical work.
For the mechanical work we refer to manufacturer instructions.
Pressurize the hydraulic circuit.
Note:
During the function, the ignition must not be switched off.
Test prerequisites:
Ignition on, engine off.
Gear in neutral.
All electrical loads should be switched off.
Battery voltage above 12 Volts.
Procedure:
Start the function, press OK.
The system is now pressurized.
A dialog box presents: operation succeeded/ failed.
If the function fails, check the test prerequisites and repair possible fault codes.
Exit the function.
Bleeding of the hydraulic circuit.
Note:
During the function, the ignition must not be switched off.
Test prerequisites:
Ignition on, engine off.
Gear in neutral.
All electrical loads should be switched off.
Battery voltage above 12 Volts.
Procedure:
Start the function, press OK.
Bleeding of the hydralic unit is now performed.
A dialog box presents: operation succeeded/ failed.
If the function fails, check the test prerequisites and repair possible fault codes.
Exit the function.
Reinitialisation of the auto-programming values.
Test prerequisites:
Ignition on, engine off.
Gear in neutral.
All electrical loads should be switched off.
Battery voltage above 12 Volts.
Procedure:
Start the function, press OK.
The auto-programming values are now reinitialised.
A dialog box presents: operation succeeded/ failed.
If the function fails, check the test prerequisites and repair possible fault codes.
Exit the function.
Programming of the clutch biting point.
Note:
During the function, the ignition must not be switched off.
Test prerequisites:
Engine on idle.
Gear in neutral.
All electrical loads should be switched off.
Procedure:
Start the function, press OK.
The programming of the clutch biting point is now started.
A dialog box presents: operation succeeded/ failed.
If the function fails, check the test prerequisites and repair possible fault codes.
Exit the function.
Programming of the gearbox grid.
Note:
During the function, the ignition must not be switched off.
Test prerequisites:
Ignition on, engine off.
Gear in neutral.
All electrical loads should be switched off.
Battery voltage above 12 Volts.
Procedure:
Start the function, press OK.
The programming of the gearbox grid is now started.
A dialog box presents: operation succeeded/ failed.
If the function fails, check test prerequisites and repair possible fault codes.
Exit the function.
Clear counters.
Note:
When changing components in the gearbox, it is possible to clear the counter values for the corresponding part. This is done to get a correct usage history of the mounted parts. Current values can be seen in datalist tables. Clear only the counter for the charged component.
Test prerequisites:
Ignition on, engine off.
All electrical loads should be switched off.
Battery voltage above 12 Volts.
Procedure:
Start the function, press OK.
A dialog box presents: operation succeeded/ failed.
If the function fails, check the test prerequisites and repair possible fault codes.
Exit the function.