Daimler India Commercial Vehicles Pvt. Ltd.

Transmission failure check list

Vehicle details
PCR ref no Date
Model
VIN no Aggregate Sl no
Complaint reported
Complaint status Only while running/ While engagement
Complaint gear gears/ All Gears
Complaint Noticed While vehicle static/ Vehicle Running
Kms Hours
Application
Operation cycle City/ Ghat/Highway/River bed/Mines site/Quary site
Pay Load & load carried
Failure observation phase Progressive/ Abrupt
Any previous attention of clutch system
Driver skill Trianed/ New driver

External check points

Clutch pedal free play mm Clutch pedal full stroke mm

Clutch pedal condition Spongy/ Free/ Hard

Gear shifting Smooth/ Hard/ Noisy

After removal of gear shift lever rubber boot Problem exist/ No complaint

After isolating the linkage Problem exist/ No complaint

(After removal of linkage - directly engage the gear by manual @ Transmission)
Position of shift lever in Neutral position mm
(Refer picture in Referrence drawing sheet - Only for G85/6)
Detent plunger Torque NM Detent bolt Modified (F551778)/ Unmodified (F227107)
(Only for G85/6) (Identification mark)
If complaint exist only on low gear/ High gear Yes/ No
(If Yes - check for tightness of grub screw - Refer Picture on referrence drawing)
Any metal particles observed Yes/ No

Reference Value - Refer Next sheet

X Direction (mm) Y Direction (mm) X Direction (mm) Y Direction (mm)

Gear Shift lever section Gear Shift lever section Gear Shift lever section Gear Shift lever section
center to cabin cut-out center to cabin cut-out center to nearest cabin center to nearest cabin
cut-out cut-out
Neutral 1 (N1) +X: 84 +Y: 73
(Assembly tool setting) - X: 96 - Y: 70 Neutral (N) +X: 84 +Y: 73
Neutral (Assembly tool setting) - X: 96 - Y: 70
42
Plane: Reverse-Crawler
Neutral
Neutral 44
Plane: Reverse
48
Plane: 7th - 8th
Neutral
67
Reverse Gear 40 43 Plane: 5th-6th

Crawler Gear 61 39 Reverse Gear 35 29

1st Gear 45 1st Gear 21 51

2nd Gear 65 2nd Gear 39

3rd Gear 48 3rd Gear 25

4th Gear 66 4th Gear 42

5th Gear 48 5th Gear 26 63

6th Gear 66 6th Gear 43 64

7th Gear 45 44

8th Gear 60 64

Prepared by
Version - DICV/T/IMA/GB/Transmission-01 Approved by
 Daimler India Commercial Vehicles Pvt. Ltd.

Transmission failure check list

Gear linkage G85/6

G85/6
position
Standard Actual Difference
X Y X Y X Y
Neutral 83 73 -83 -73
With assy tool -96 -70 96 70
Neutral plane:
Reverse gear - 44 - -44
Neutral plane:
67 - -67 -
5th-6th
Reverse gear 35 29 -35 -29
1st Gear 21 51 -21 -51
2nd Gear 39 - -39 -
3rd Gear 25 - -25 -
4th Gear 42 - -42 -
5th Gear 26 63 -26 -63
6th Gear 43 64 -43 -64

Gear linkage
G131/6
position
G131/6
Standard Actual Difference
X Y X Y X Y
Neutral(N1) 84 73 -84 -73
With assy tool -96 -70 96 70
Neutral plane:
Reverse/ Crawler - 42 - -42
gear
Neutral plane:
- 48 -48
7th-8th
Reverse gear 40 43 -40 -43
Crawler gear 61 39 -61 -39
1st Gear 45 - -45 -
2nd Gear 65 - -65 -
3rd Gear 48 - -48 -
4th Gear 66 - -66 -
5th Gear 48 - -48 -
6th Gear 66 - -66 -
7th Gear 45 44 -45 -44
8th Gear 60 64 -60 -64

Prepared by
Version - DICV/T/IMA/GB/Transmission-01 Approved by
 Daimler India Commercial Vehicles Pvt. Ltd.

Position of shift lever in Neutral position - G85/6

Tightness of Grub screw - G131/9

LH side of the casing

Prepared by
Version - DICV/T/IMA/GB/Transmission-01 Approved by