Bert Rowe’smercedesBenz ‘A’class info Gearbox (Manual) Dumbbell…

10 Апр 2015 | Author: | No comments yet »
Mercedes-Benz A 160 W168

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..


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 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


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.


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.


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:-

in mind that this will only arise if the is removed without the manual being placed into gear.

1. Select neutral

2. the newly installed reversing

3 .Using your Pen magnet by it through the switch location raise the ‘PLATE’ A seen in the above,

4. Secure or get a third party to in position while reverse is selected in the cab.

5. Remove the

6. Replace reverse light

Mercedes-Benz A 160 W168

7. Test, Satisfactory, Job done.

sure that if you have to error of removing the switch selecting reverse gear you want to thank David for us all in his method of overcoming what is a difficult situation and one that Workshops will want to the most of if you take your car to for repair.

David came up this procedure after had to remove the selector to cure the on his car a difficult and time consuming which is best avoided.

Aug Are you better getting you work by Mercedes Benz.

I received a from a distressed owner, his car has into a Mercedes Workshop in land Spain who have his reversing light switch, to find that when he the car the reversing light was still on, though the new switch had been

he was now requesting help, as the garage the cause was now a defective selector .

I him back and asked if he had also the use of some gears, yes he had but at the time of wasn’t aware of it, he now even distressed.

I mailed him Explaining the garage had not used the Mercedes work shop procedure to fit the and that there was now ever the selector would be damaged.

To my the garage informed him that the gear lever to reverse when changing the switch was and that they had not damaged

We exchanged several mails me suggesting that unless the sorted the problem they had now he would be better taking the car to MB garage and then giving the to the MB repairer who did the work and caused the

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

Having now sent him the which clearly states gear must be selected and throughout the repair or the selector be damaged, they now decided to another look at his car at no cost to and yes they removed and found the damaged but repairable in that the that blocks you going reverse gear inadvertently was but could be straightened.

On returning the and having followed the correct the second time around all was and the light now switched off when than reverse gear is

So be warned it’s happened it will happen again, the lever MUST be placed in position and remain there the repair. Fail to do that and you this garage will certainly damage the selector. If the work done at any Garage you be well advised to tell of the procedure required or you well the same after problems.

The right shows the selector, switch located, on the plate B it that the damage was cussed in the of C I myself suspect it was simply a of re-locating the plate which 3rd and 5th gears to be obtained and the switch to and thus the reversing light to when reverse is selected

If you are difficulty in obtaining gears

If you are difficulty in obtaining gears try this re-set procedure:- by SVC Sergio, if you would like to the SVC site member then send them you name with a request to them and they will you a password which will you to post information and questions.

posted the following information on MB ACS and manual gear boxes.

with the simplicity of this he personally did research and found the suggested procedure does and due to its importance I felt it would be to owners if I posted it on his site, As we have a common aim I know he not mind me copying it to this

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. Press the brake pedal.

3. the first gear, you may hear inside the wing. This is the push-rod moving within the ACS

4. Return to gear lever to (*).

5. Release the brake

6. Press the brake.

7. Engage the gear (*)

8. Return to gear to neutral (*).

9. Finally the brake pedal.

10. Release the brake lever, turn off and the ignition key .

11. Re-apply hand remove chocks

Even the engine off, the clutch system is always energized but in mode and following the script it will learn the correct of the clutch drive plate.

So, if you let children play with the lever, or even yourself the gear lever just for fun and pressing the brake pedal, in the you (or your children or anyone are misadjusting all the system.

Remember this fully computerized clutch is very delicate and a system, not a toy and should be used for driving.

Do not ever play the gear lever and do not allow to to do that, if the engine is off.

For the manual system, do the same instead of brake pedal, use the pedal.


John’s Gearbox

This photo the main bearings that causing the noise in the johns with new and the noise is gone.

claim that the oil in the gearbox not need replacing, however in my it is worth while changing oil and ensuring it is to the correct level.

the car on level standing ,top plug removed, the oil should be up to the edge of the filler hole.

It is measuring the amount you remove if the fluid if only to prove the oil level is low as it was in my own case.

The oil drains from the Gear box lower removed, if the fluid is warm following a run.

This the reverse gear and differentional in part of the gear box casing.

shows the gear selector from the top of the gearbox, it is this the houses the reverse ing light To prevent this unit being damaged while the reversing lamp switch the MUST be placed into and in reveres gear until the new is fully fitted.

See above if you already fallen foul of procedure.

This photo the main shafts and gears

This shows one of the syncromesh fitted into the gearbox allow drivers to move one gear to another smoothly.

to syncromesh gears being to gera boxes the engine and gearbox speed had to be judged by the to prevent the gears grinding against on e another as they to mesh one to the other.

Commercial were the last to be fitted syncromesh, and thus the term boxes was used by drivers, an driving feature was to double-de-clutch

the was depressed, the gearlever was moved to the clutch was again depressed and the gear selected, providing the speed was correct a smooth of gear could then be with no noise.

These doubling the clutch is not required vehicles including commecial, automatics, all manual gearboxes are now with syncromesh gears.

photo shows the Gearbox assembled.

Thank you John photographs, you saved yourself a

Just in passing John discovered that the injectors on diesel car had been leaking caused as much work however having the engine out of the car the job easier and he was able to do both at the same time.

The tool by John for fitting the poly V can be seen on page 57. along an injector re-seating tool on

The sort of Mechanic all ‘A’ Models should come with!

Mercedes-Benz A 160 W168
Mercedes-Benz A 160 W168
Mercedes-Benz A 160 W168
Mercedes-Benz A 160 W168
Mercedes-Benz A 160 W168

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