Service

Workshop Manual
Crafter 2006 ➤
Shiftmatic automated gearbox 0B8
Edition 09.2012

Service Department. Technical Information

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 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 General repair instructions for gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Gaskets, seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.5 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.6 Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.7 Synchro-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.8 Gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Allocation of gearbox to engine, gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Clutch operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Removing and installing clutch slave cylinder together with release bearing . . . . . . . . . . . . 5
1.2 Removing and installing clutch travel sender G162 for slave cylinder with release bearing
........................................................................ 6
2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Resetting adjusting ring of self-adjusting pressure plate . . . . . . . . . . . . . . . . . . . . . . . . . . 10

34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Removing and installing selector lever E313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Removing and installing gearbox hydraulic pressure sender G270 . . . . . . . . . . . . . . . . . . 16
1.4 Removing and installing pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 Disposing of pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.6 Removing and installing gearbox speed sender G38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7 Removing and installing gear detection sensor G604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.8 Removing and installing electronic manual gearbox control unit J514 . . . . . . . . . . . . . . . . 23
1.9 Table - adapting components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.10 Removing and installing pan for hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.11 Removing and installing hydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.12 Removing and installing gearbox hydraulic pressure sender V387 . . . . . . . . . . . . . . . . . . 34
1.13 Checking hydraulic fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.14 Draining and filling hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.1 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.2 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.1 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1 Renewing sealing cover in gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.2 Removing and installing gearbox breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5 Gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Contents i
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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

5.2 Draining and filling gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.1 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.1 Renewing output shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

ii Contents
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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

00 – Technical data
1 Identification
(VRL005142; Edition 09.2012)
⇒ “1.1 Gearbox identification”, page 1

1.1 Gearbox identification

The Shiftmatic automated manual gearbox 0B8 is installed in the
Crafter 2006 ► in conjunction with a 5-cylinder diesel engine.
The gearbox code is stated on the data sticker ⇒ Maintenance ;
Booklet 10.2 .
Only the part number appears on the gearbox.
Part number -arrow-

1. Identification 1
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2 Repair instructions
⇒ “2.1 General repair instructions for gearboxes”, page 2
⇒ “2.2 Gaskets, seals”, page 2
⇒ “2.3 Locking devices”, page 3
⇒ “2.4 Nuts and bolts”, page 3
⇒ “2.5 Bearings”, page 3
⇒ “2.6 Shims”, page 3
⇒ “2.7 Synchro-rings”, page 3
⇒ “2.8 Gear wheels”, page 3

2.1 General repair instructions for gearbox‐

es
To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Of course, the basic rules for safety also apply dur‐
ing repair work.
A number of generally applicable instructions for the various re‐
pair procedures which were previously repeated at numerous
places in the workshop manual are summarised here. They apply
to this workshop manual.
♦ During installation, ensure that the dowel sleeves between the
engine and gearbox are correctly located.
♦ When exchanging a Shiftmatic automated manual gearbox, fill
with gear oil to lower edge of filler hole and check hydraulic
fluid level.
♦ Gearbox capacity ⇒ page 51 .
♦ Quantity of hydraulic fluid ⇒ page 35 .
♦ Gear oil specification ⇒ Maintenance ; Booklet 10.2

2.2 Gaskets, seals

♦ Thoroughly clean parting surfaces and apply sealing paste -
AMV 188 200 03- .
♦ Apply sealing paste uniformly but not too thick.
♦ Renew O-rings.
♦ Radial oil seals.
Before installing radial oil seals:
Lightly oil outer diameter and half-fill space between sealing lips
-arrow- with grease -G 052 128 A1- .
After installation:
♦ Check oil level and top up if necessary ⇒ page 51 .

2 Rep. gr.00 - Technical data

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 Crafter 2006 ➤
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2.3 Locking devices

♦ Renew retaining rings.
♦ Do not overstretch retaining rings.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position: slot longitudinal to line
of force.

2.4 Nuts and bolts

♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Do not cant especially delicate parts, such as clutch pressure
plates. Loosen and tighten bolts and nuts in stages in a diag‐
onal sequence.
♦ Specified torques settings are specified for unoiled bolts and
nuts.
♦ Always renew self-locking bolts and nuts.

2.5 Bearings
♦ Install needle bearings with lettered side towards fitting tool.

2.6 Shims
♦ Measure shims at several points with a micrometer. The var‐
ious thicknesses make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.

2.7 Synchro-rings
♦ Do not interchange synchro-rings.
♦ When reusing synchro-rings, always fit to the same gear.
♦ Check for wear and renew if necessary.
♦ Moisten with gear oil before installing.

2.8 Gear wheels

♦ Before installing, clean and heat on a hot plate to approx.
100° C.
♦ The temperature can be checked with thermometer -V.A.G
1558- , ignition tester -V.A.G 1767- or diesel tester -V.A.G
1743- .

2. Repair instructions 3
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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

3 Technical data
⇒ “3.1 Allocation of gearbox to engine, gear ratios”, page 4

3.1 Allocation of gearbox to engine, gear ra‐

tios
Shiftmatic automa‐ 0B8
ted gearbox
Identification code HRF
Allocation Model Crafter
Engine code: BJK 2.5 I - 80 kW
Engine code: BJL 2.5 I - 100 kW
Ratio:
Constant mesh 3925 ik = 1.56
gears
1st gear 3925x4514 i1 = 5.014
2nd gear 3925x4927 i2 = 2.831
3rd gear 3925x3934 i3 = 1.789
4th gear 3925x3341 i4 = 1.256
5th gear i5 = 1.0
6th gear 3925x2447 i6 = 0.797
Reverse gear 3925x2323x4114 iR = 4.569
Speedometer electronic
Capacity Manual gearbox 1.5 l
Hydraulic unit 0.5 l
Specification ⇒ Maintenance ; Booklet 10.2
Clutch operation Electronic/hydraulic
Clutch plate ∅ 240 mm

4 Rep. gr.00 - Technical data

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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

30 – Clutch
1 Clutch operation
⇒ “1.1 Removing and installing clutch slave cylinder together with
release bearing”, page 5
⇒ “1.2 Removing and installing clutch travel sender G162 for slave
cylinder with release bearing”, page 6

1.1 Removing and installing clutch slave

cylinder together with release bearing
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

Removing
– Remove Shiftmatic automated manual gearbox ⇒ page 41 .
– Separate connector for clutch travel sender -G162- -1-.

– Pry securing clip -1- out of hydraulic line using a small screw‐
driver.
– Pull out hydraulic line.

Note

To prevent hydraulic fluid from escaping, seal the pulled-off hy‐

draulic line using, for example, the sealing cap from the brake
bleeder valve.

1. Clutch operation 5
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 Crafter 2006 ➤
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– Remove bolts -1- and remove slave cylinder with release bear‐
ing -2-.

Note

♦ Do not apply compressed air to removed slave cylinder with

release bearing because it can be pressed apart and de‐
stroyed.
♦ The slave cylinder with release bearing is a single component.

Installing
Install in reverse order of removal, observing the following:

Note

In spite of a bleeder valve on the slave cylinder with release bear‐

ing, no bleeding should be carried out because the entire hy‐
draulic system for the gearbox including the clutch is self-
bleeding.

Specified torques
♦ ⇒ “2.1 Specified torques for gearbox”, page 41
Component Specified torque
Securing bolts for slave cylin‐ 9 Nm
der with clutch release bearing
– Check hydraulic fluid level and top up if necessary
⇒ page 35 .
– Carry out the function “Learn clutch release point” ⇒ Vehicle
diagnostic tester.

1.2 Removing and installing clutch travel

sender -G162- for slave cylinder with re‐
lease bearing
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1783-

6 Rep. gr.30 - Clutch

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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

Removing
– Remove Shiftmatic automated manual gearbox ⇒ page 41 .
– Separate connector for clutch travel sender -G162- -1-.

– Release wiring for clutch travel sender -G162- -1-.

– Remove securing nuts -2- and pull off clutch travel sender -
G162- .
Installing
Install in reverse order of removal, observing the following:
– Carry out the function “Learn clutch release point” ⇒ Vehicle
diagnostic tester.
Specified torques
♦ ⇒ “2.1 Specified torques for gearbox”, page 41
Component Specified torque
Securing bolts for clutch travel 3 Nm
sender -G162-

1. Clutch operation 7
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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

2 Clutch
⇒ “2.1 Assembly overview - clutch”, page 8
⇒ “2.2 Removing and installing clutch”, page 8
⇒ “2.3 Resetting adjusting ring of self-adjusting pressure plate”,
page 10

2.1 Assembly overview - clutch

1 - Flywheel
❑ Ensure that centring
pins fit tightly
❑ Contact surfaces for
clutch lining must be
free of grooves, oil and
grease
❑ Removing and installing
⇒ Cylinder block (gear‐
box end); Rep. gr. 13 ;
Removing and installing
flywheel .
2 - Clutch plate

Note

Installation position of clutch plate:

lettering “Getriebsseite” must face
gearbox.
❑ Centring ⇒ page 10
❑ Lightly grease splines
3 - Pressure plate
❑ Removing and installing
⇒ page 8 .
❑ Check ends of dia‐
phragm spring
⇒ page 10
4 - Bolt
❑ Loosen or tighten diag‐
onally and in steps
❑ 22 Nm

2.2 Removing and installing clutch

Special tools and workshop equipment required

8 Rep. gr.30 - Clutch

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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

♦ Torque wrench -V.A.G 1331-

♦ Centring mandrel -3434-

♦ Counterhold tool -3386-

Note

If vehicle is manoeuvred for a longer time with a slipping clutch,

the temperature of the clutch will rise. There is a two-stage clutch-
protection function to warn of critical temperatures. Above a cal‐
culated clutch temperature of 250 °C, the clutch will be closed
faster when the vehicle is driven off. If the calculated clutch tem‐
perature exceeds 300 °C, the driver is warned by a hard jolt from
the clutch when driving off. If the drive ignores this warning and
continues to overload the clutch, the clutch will be destroyed.

2. Clutch 9
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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

– Remove Shiftmatic automated manual gearbox ⇒ page 41 .

Centring clutch plate and removing and installing pressure plate
– Fit counterhold tool -3386- .
– Loosen or tighten bolts diagonally in stages.
Installing
Install in reverse order of removal, observing the following:

Note

♦ Pressure plate contact surface and clutch plate lining must

make full contact with flywheel.
♦ Tighten securing bolts diagonally and evenly to prevent dam‐
age to pressure plate centring hole and flywheel centring pins.
♦ Renew clutch plates and pressure plates with damaged or
loose rivets.
♦ Select clutch plate and pressure plate according to ⇒ Elec‐
tronic parts catalogue “ETKA” and engine codes.

Checking ends of diaphragm spring -arrows-

• Wear up to half the thickness of the diaphragm spring is per‐
mitted.
– Carry out the functions “Learn clutch release point” and “Learn
gearbox shift position” ⇒ Vehicle diagnostic tester.
Specified torques
♦ ⇒ “2.1 Assembly overview - clutch”, page 8
♦ ⇒ “2.1 Specified torques for gearbox”, page 41

2.3 Resetting adjusting ring of self-adjusting

pressure plate
Special tools and workshop equipment required
♦ Press tool -VW 412-

10 Rep. gr.30 - Clutch

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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

♦ Thrust pad -3062-

Note

♦ Only when a new clutch plate is installed with a used self-ad‐

justing pressure plate should the adjusting ring be reset to
stop.
♦ If the adjusting ring is not reset, clutch pressure will be reduced
and cause an increase in clutch plate wear.
♦ If the clutch plate is not renewed, the adjusting ring need not
be reset. New pressure plates are already adjusted.

– Centre thrust pad -3062- in middle of pressure plate.

Note

Do not use force when performing the following work:

2. Clutch 11
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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

– Apply two screwdrivers to forks on adjusting ring.

– Press down on pressure plate with press until adjusting ring
can just be moved.
– Using the two screwdrivers, turn back adjusting ring evenly in
-direction of arrow- to stop.
– Hold adjusting ring against stop and reduce pressure exerted
by the press so that adjusting ring is held in this position.

12 Rep. gr.30 - Clutch

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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

34 – Controls, housing
1 Selector mechanism
⇒ “1.1 Overview - selector mechanism”, page 13
⇒ “1.2 Removing and installing selector lever E313 ”, page 14
⇒ “1.3 Removing and installing gearbox hydraulic pressure send‐
er G270 ”, page 16
⇒ “1.4 Removing and installing pressure accumulator”,
page 16
⇒ “1.5 Disposing of pressure accumulator”, page 18
⇒ “1.6 Removing and installing gearbox speed sender G38 ”,
page 18
⇒ “1.7 Removing and installing gear detection sensor G604 ”,
page 19
⇒ “1.8 Removing and installing electronic manual gearbox control
unit J514 ”, page 23
⇒ “1.9 Table - adapting components”, page 23
⇒ “1.10 Removing and installing pan for hydraulic fluid”,
page 24
⇒ “1.11 Removing and installing hydraulic control unit”,
page 26
⇒ “1.12 Removing and installing gearbox hydraulic pressure
sender V387 ”, page 34
⇒ “1.13 Checking hydraulic fluid level”, page 35
⇒ “1.14 Draining and filling hydraulic fluid”, page 37

1.1 Overview - selector mechanism

1. Selector mechanism 13
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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

1 - Selector lever -E313-

❑ Removing and installing
⇒ page 13 .
2 - Gearbox speed sender -
G38-
❑ Removing and installing
⇒ page 18 .
3 - Gearbox breather
❑ Removing and installing
⇒ page 50 .
4 - Gear detection sensor -
G604-
❑ Removing and installing
⇒ page 19 .
5 - Angled magnet
❑ Removing and installing
⇒ page 26 .
6 - Hydraulic pump for gearbox
-V387-
❑ Removing and installing
⇒ page 34 .
7 - Pressure accumulator
❑ Removing and installing
⇒ page 16 .
❑ Remove and install with
gearbox hydraulic pres‐
sure sender -G270-
⇒ page 16
8 - Diagnostic connection
❑ Connecting
⇒ page 23
9 - Hydraulic control unit
❑ Removing and installing ⇒ page 26 .
10 - Pan for hydraulic fluid
❑ Removing and installing ⇒ page 24 .
11 - Electronic manual gearbox control unit -J514-
❑ Removing and installing ⇒ page 23 .
12 - Wiring harness
13 - Slave cylinder with clutch release bearing
❑ Removing and installing ⇒ page 5 .
❑ With clutch travel sender -G162-

1.2 Removing and installing selector lever -

E313-
Special tools and workshop equipment required

14 Rep. gr.34 - Controls, housing

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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

♦ Torque wrench -V.A.G 1331-

Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting battery .
Gearbox must be in neutral.
– Release clips from selector lever cover -arrows- and pull them
upwards.
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 70 ; Trim, insulation .

– Remove securing bolts -A-.

– Separate wiring harness connection and remove selector lev‐
er -E313- .
Installing
Install in reverse order of removal, observing the following:
– Carry out the function “Learn gearbox shift position” ⇒ Vehicle
diagnostic tester.
Specified torques
♦ Battery; Disconnecting and connecting battery ⇒ Rep. gr. 27 ;
Disconnecting and connecting battery
♦ Dash panel; Removing and installing dash panel ⇒ Rep. gr.
70 ; Dash panel
Component Specified torque
Selector lever -E313- to dash 20 Nm
panel

1. Selector mechanism 15
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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

1.3 Removing and installing gearbox hy‐

draulic pressure sender -G270-
Removing
– Carry out the function “Relieving pressure, gearbox hydraul‐
ics” ⇒ Vehicle diagnostic tester.
– Remove securing bolts -2- and pull cover -1- downwards out
of guide -arrow-.

– Separate connector -1-.

Note

♦ Separating connector -1- will prevent unintentional starting of

hydraulic pump for gearbox -V387- .
♦ Connector -2- is not to be separated.

– Pull off connector -1- and screw out gearbox hydraulic pres‐
sure sender -G270- -2-.
Installing
Install in reverse order of removal, observing the following:

– Before reconnecting separated connector -1- for hydraulic

pump for gearbox -V387- , check hydraulic fluid level and top
up as required ⇒ page 35 .
Specified torque
Component Specified torque
Gearbox hydraulic pressure 3 Nm
sender -G270-

1.4 Removing and installing pressure accu‐

mulator
Special tools and workshop equipment required

16 Rep. gr.34 - Controls, housing

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♦ Torque wrench -V.A.G 1331-

Removing
– Carry out the function “Relieving pressure, gearbox hydraul‐
ics” ⇒ Vehicle diagnostic tester.
– Remove securing bolts -2- and pull cover -1- downwards off
guide -arrow-.

– Separate connector -1-.

Note

♦ Separating connector -1- will prevent unintentional starting of

hydraulic pump for gearbox -V387- .
♦ Connector -2- is not to be separated.

– Unbolt pressure line -1- from pressure accumulator -7-.

– Pull breather hose -2- off breather valve -4-.
– Turn breather valve -4- about 45° to the right and pull it out.
– Separate connector -8- from gearbox hydraulic pressure send‐
er -G270- .
– Remove bolts -5- from retaining clip -6- and remove pressure
accumulator -7-.
Installing
Install in reverse order of removal, observing the following:

1. Selector mechanism 17
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– Before reconnecting separated connector -1- for hydraulic

pump for gearbox -V387- , check hydraulic fluid level and top
up as required ⇒ page 35 .
Specified torque
Component Specified torque
Securing bolts -5- for retaining 15 Nm
clip
Pressure line -1- to gearbox hy‐ 16 Nm
draulic pressure sender -G270-
Disposing of pressure accumulator ⇒ page 18 .

1.5 Disposing of pressure accumulator

– Drain remaining hydraulic fluid from pressure accumulator into
an appropriate container.

Note

Observe regulations for disposing of hydraulic fluid.

– Clamp pressure accumulator in vice.

– Using a 2 mm drill bit, drill a hole in the pressure accumulator
about 15 mm -A- from welded seam.
The remaining gas charge will escape.
The pressure accumulator may now be disposed of.

1.6 Removing and installing gearbox speed

sender -G38-
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

18 Rep. gr.34 - Controls, housing

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Removing
– Separate connector -1-.
– Remove securing bolt -2- and pull off gearbox speed sender -
G38- -3-.

Note

The O-ring -4- may remain in the gearbox housing when the gear‐
box speed sender -G38- -3- is removed.

Installing
Install in reverse order of removal, observing the following:

Note

♦ It may be necessary to recut the thread in the gearbox housing

for the securing bolt -2-.
♦ Fit gearbox speed sender -G38- with new seal and new se‐
curing bolts.

Specified torque
Component Specified torque
Securing bolt for gearbox 8 Nm
speed sender -G38-

1.7 Removing and installing gear detection sensor -G604-

1. Selector mechanism 19
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Special tools and workshop

equipment required
♦ Engine strut -T50015-
♦ Torque wrench -V.A.G
1783-
♦ Torque wrench -V.A.G
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-

Removing
– Shift gearbox to “N” position.
– Unbolt propshaft -A- from gearbox flange and secure prop‐
shaft to body using e.g. baling wire.

20 Rep. gr.34 - Controls, housing

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– Loosen securing clamp on exhaust pipe -1- and press exhaust

system -2- off front exhaust pipe -arrow-.

Note

♦ Do not move exhaust filter, or the exhaust pipe will leak ⇒

Power unit; Rep. gr. 26 ; Exhaust system .
♦ Securing clamp -1- must always be renewed.

– Position engine and gearbox jack -V.A.G 1383 A- with gearbox

support -V.A.G 1359/2- under gearbox.

– Remove bolts -1- and -2- for gearbox carrier.

Note

♦ Mark the installation position of the gearbox carrier.

♦ Depending on construction, there may be four securing bolts
-2- for the gearbox mounting.

– Lower gearbox using engine and gearbox jack -V.A.G 1383 A-

far enough that securing bolts -2- for gear detection sensor -
G604- -1- can be removed.

1. Selector mechanism 21
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– Attach engine strut -T50015- to available holes -arrow-.

Note

♦ Depending on construction, other components associated

with optional equipment may be attached to the securing
points -arrows- for the engine support -T50015- .
♦ These additional components must be removed according to
the instructions in the respective workshop manuals.

– Turn spindle on engine strut -T50015- to bring engine to in‐

stallation position.

Caution

It is not permitted to support the engine between the sump and

the steering box.
This manner of support can lead to damage to the steering box.
As a consequence, hydraulic fluid leaks may develop in the
steering box, leading to the failure of power steering.
To avoid this, use engine strut -T50015- to support the engine.

– Unclip connector -3- from gear detection sensor -G604- -1-

and remove securing bolts -2-.
Installing
Install in reverse order of removal, observing the following:

Note

The sealing surface of the gear detection sensor -G604- must be

free of oil and grease.

– Apply sealant ⇒ Electronic parts catalogue “ETKA” to sealing

surfaces of gearbox housing and fit gear detection sensor -
G604- .
– Place gearbox carrier in its previously marked position.
– Teach gearbox shift position to gear detection sensor -G604-
⇒ Vehicle diagnostic tester.
Specified torque
♦ Exhaust system; exhaust pipes and silencers ⇒ Rep. gr. 26 ;
Exhaust pipes/silencers .
♦ Propshaft, Assembly overview, propshaft ⇒ Rep. gr. 39 ;
Propshaft
Component Specified torque
Securing bolts for gear detec‐ 3 Nm
tion sensor -G604-
Securing bolts for propshaft 100 Nm
safety bar
Securing bolt for gearbox carri‐ 58 Nm
er

22 Rep. gr.34 - Controls, housing

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1.8 Removing and installing electronic man‐

ual gearbox control unit -J514-
Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting battery .

Note

It may be necessary to remove driver seat due to optional equip‐

ment ⇒ Body Repairs; Rep. gr. 72 ; Removing and installing front
seat with fore-and-aft adjustment .

– Pull connector off electronic manual gearbox control unit -

J514- -arrow- -B-.
– Remove securing bolts -A- and remove electronic manual
gearbox control unit -J514- -B-.
Installing
Install in reverse order of removal, observing the following:
– Encoding electronic manual gearbox control unit -J514- ⇒ Ve‐
hicle diagnostic tester.

1.9 Table - adapting components

Procedure
– Release securing screw -1- using e.g. screwdriver and open
dash panel cover on left side.
– Connect ⇒ Vehicle diagnostic tester and select test program.

Note

“Adaptation of clutch for wear” is performed automatically by the

electronic manual gearbox control unit -J514- during travel.

Task Learn clutch release Learn gearbox se‐ Renew and code Relieving pressure,
point lector settings control unit gearbox hydraulics
Removing and in‐ X X
stalling clutch; re‐
newing as necessary
Removing and in‐ X X
stalling slave cylin‐
der with release
bearing; renewing as
necessary
Removing and in‐ X X
stalling clutch travel
sender -G162- ; re‐
newing as necessary

1. Selector mechanism 23
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Task Learn clutch release Learn gearbox se‐ Renew and code Relieving pressure,
point lector settings control unit gearbox hydraulics
Removing and in‐ X
stalling selector lever
-E313- ; renewing as
necessary
Removing and in‐ X X
stalling gearbox hy‐
draulic pressure
sender -G270- ; re‐
newing as necessary
Removing and in‐ X X
stalling pressure ac‐
cumulator; renewing
as necessary
Removing and in‐ X
stalling gear detector
sensor -G604- ; re‐
newing as necessary
Removing and in‐ X
stalling electronic
manual gearbox
control unit -J514- ;
renewing as neces‐
sary
Removing and in‐ X X
stalling or renewing
hydraulic control unit
Removing and in‐ X X
stalling pan for hy‐
draulic fluid
Checking hydraulic X X
fluid level and toping
up if necessary
Changing hydraulic X X
fluid
Removing and in‐ X X
stalling gearbox hy‐
draulic pressure
sender -V387-
Removing and in‐ X X
stalling Shiftmatic
automatic manual
gearbox

1.10 Removing and installing pan for hydraul‐

ic fluid
Special tools and workshop equipment required

24 Rep. gr.34 - Controls, housing

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♦ Engine and gearbox jack -V.A.G 1383 A-

♦ Torque wrench -V.A.G 1331-

Removing
– Carry out the function “Relieving pressure, gearbox hydraul‐
ics” ⇒ Vehicle diagnostic tester.
– Remove securing bolts -2- and pull cover -1- downwards out
of guide -arrow-.

– Separate connector -1-.

Note

♦ Separating connector -1- will prevent unintentional starting of

hydraulic pump for gearbox -V387- .
♦ Connector -2- is not to be separated.

1. Selector mechanism 25
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– Position engine and gearbox jack -V.A.G 1383 A- with gearbox

support -V.A.G 1359/2- under gearbox.

– Remove bolts -1- and -2- and remove gearbox carrier.

Note

♦ Mark the installation position of the gearbox carrier.

♦ Depending on construction, there may be four securing bolts
-2- for the gearbox mounting.

– Drain hydraulic fluid ⇒ page 37 .

– Remove suction line -3- and -4- return line from pan.
– Remove securing bolts -2- and remove pan -1-.
Installing
Install in reverse order of removal, observing the following:

Note

The sealing surfaces of the pan and the gearbox housing must
be free of oil and grease.

– Apply sealant ⇒ Electronic parts catalogue “ETKA” to sealing

surfaces of gearbox housing and fit sump.

– Before reconnecting separated connector -1- for hydraulic

pump for gearbox -V387- , “fill” with hydraulic fluid,
⇒ page 37 Changing hydraulic fluid.
Specified torque
Component Specified torque
Pan to gearbox housing 9.5 Nm
Gearbox mounting to gearbox 30 Nm
carrier M8x20
Gearbox mounting to gearbox 45 Nm
M10x25

1.11 Removing and installing hydraulic con‐

trol unit
Special tools and workshop equipment required

26 Rep. gr.34 - Controls, housing

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♦ Torque wrench -V.A.G 1331-

♦ Engine strut -T50015-

Removing
– Carry out the function “Relieving pressure, gearbox hydraul‐
ics” ⇒ Vehicle diagnostic tester.
– Remove securing bolts -2- and pull cover -1- downwards off
guide -arrow-.

– Separate connector -1-.

Note

♦ Separating connector -1- will prevent unintentional starting of

hydraulic pump for gearbox -V387- .
♦ Connector -2- is not to be separated.

1. Selector mechanism 27
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– Unbolt propshaft -A- from gearbox flange and secure prop‐

shaft to body using e.g. baling wire.

– Loosen securing clamp on exhaust pipe -1- and press exhaust

system -2- off front exhaust pipe -arrow-.

Note

♦ Do not move exhaust filter, or the exhaust pipe will leak ⇒

Power unit; Rep. gr. 26 ; Exhaust system .
♦ Securing clamp -1- must always be renewed.

– Position engine and gearbox jack -V.A.G 1383 A- with gearbox

support -V.A.G 1359/2- under gearbox.

– Remove securing bolts -1- and -2- for gearbox carrier.

Note

♦ Mark the installation position of the gearbox carrier.

♦ Depending on construction, there may be four securing bolts
-2- for the gearbox mounting.

28 Rep. gr.34 - Controls, housing

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– Lower gearbox using engine and gearbox jack -V.A.G 1383 A-

far enough that securing bolts -2- for gear detection sensor -
G604- -1- can be removed.

– Attach engine strut -T50015- to available holes -arrow-.

Note

♦ Depending on construction, other components associated

with optional equipment may be attached to the securing
points -arrows- for the engine support -T50015- .
♦ These additional components must be removed according to
the instructions in the respective workshop manuals.

– Turn spindle on engine strut -T50015- to bring engine to in‐

stallation position.

Caution

It is not permitted to support the engine between the sump and

the steering box.
This manner of support can lead to damage to the steering box.
As a consequence, hydraulic fluid leaks may develop in the
steering box, leading to the failure of power steering.
To avoid this, use engine strut -T50015- to support the engine.

– Unclip connector -3- from gear detection sensor -G604- -1-

and remove securing bolts -2-.

1. Selector mechanism 29
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– Remove securing bolt -1- and unclip angled magnet -2-.

Note

♦ Pull a cloth through under the centre shaft and selector sleeve
so that bolt -1- and angled magnet -2- cannot fall into the
gearbox.
♦ Do not let angled magnet -2- touch the metal magnet strip.

– Remove connecting bolt -1- from centre selector shaft.

– Remove bolt -3- for securing clamp -4-.

– Unbolt pressure line -1- from pressure accumulator -2-.

– Remove securing bolt from clamp for hydraulic line -3-.

– Pull return line -2- off connection pipe -1-.
– Remove union nut from clutch pressure line -8- on hydraulic
control unit -4-.
– Remove electrical connections -7- and -5- from solenoid
valves.
– Remove union nut from pressure line -6- on hydraulic control
unit -4-.

30 Rep. gr.34 - Controls, housing

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– Remove bolts -1- and -2-.

– Carefully lever hydraulic control unit -3- off gearbox in vicinity
of selector brake -arrow-.

Note

♦ If the pressure line -1- to the pressure accumulator must be

renewed, it must be attached near the selector brake -arrow-
at the same height as the contact surface of the securing bolts.
♦ Ensure clearance to pressure line -1-.

Installing

Install in reverse order of removal, observing the following:

Note

The sealing surfaces of the hydraulic control unit -4- and the
gearbox housing must be free of oil and grease.

– Apply sealant ⇒ Electronic parts catalogue “ETKA” to sealing

surface of gearbox.
– Set hydraulic control unit -4- in place on gearbox housing and
tighten union nuts of pressure line -6- and clutch pressure line
-8- hand tight.

– Push connecting sleeve -2- onto centre selector shaft -1-.

Note

Groove -arrow- must face upwards.

1. Selector mechanism 31
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– Push hydraulic control unit -4- further until it rests against

gearbox housing.

Note

Pull a cloth through under the centre shaft and selector sleeve so
that bolt -1- cannot fall into the gearbox.

– Secure centre selector shaft using a new connecting bolt -1-.

– Now tighten bolts -1- and -2- for hydraulic control unit -3- in the
prescribed order -A-, -B-, -C- and -D-

– Now tighten pressure line -6- and -8-.

Note

♦ Pressure line -6- must not contact gearbox housing.

♦ Do not yet push return line -2- onto connection -1-.
♦ The return line -2- will be used to add hydraulic fluid ⇒ Elec‐
tronic parts catalogue “ETKA” ⇒ page 35 ..

– Clip connections -7- and -5- onto solenoid valves.

32 Rep. gr.34 - Controls, housing

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– Tighten union nut for pressure line -1- to pressure accumulator

-2-.
– Attach line clamp -4- and tighten securing bolt -3-.

– Clip in angled magnet -2-.

Note

Do not let angled magnet -2- touch the metal magnet strip.

– Now install securing bolt -1-.

– Apply sealant ⇒ Electronic parts catalogue “ETKA” to sealing
surfaces of gearbox housing and fit gear detection sensor -
G604- .

Note

The sealing surface of the gear detection sensor -G604- must be

free of oil and grease.

– Place gearbox carrier in its previously marked position.

– Install exhaust system with new securing clamp.

1. Selector mechanism 33
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– Before reconnecting separated connector -1- for hydraulic

pump for gearbox -V387- , check hydraulic fluid level and top
up as required ⇒ page 35 .
Specified torque
Component Specified torque
Hydraulic control unit pressure 16 Nm
line to pressure accumulator
Hydraulic pump pressure line to 16 Nm
hydraulic control unit
Clutch line to hydraulic control 16 Nm
unit
Securing bolts on bottom of hy‐ 9.5 Nm
draulic control unit to gearbox
Securing bolts on top of hy‐ 7.5 Nm
draulic control unit to gearbox
Securing bolt for connecting 11.5 Nm
sleeve to centre selector shaft
Securing bolt for angled mag‐ 3 Nm
net to connecting sleeve
Connecting hose retainer to hy‐ 6 Nm
draulic control unit
♦ Exhaust system; exhaust pipes and silencers ⇒ Rep. gr. 26 ;
Exhaust pipes/silencers .
♦ Propshaft, Assembly overview, propshaft ⇒ Rep. gr. 39 ;
Propshaft

1.12 Removing and installing gearbox hy‐

draulic pressure sender -V387-
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

34 Rep. gr.34 - Controls, housing

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 Crafter 2006 ➤
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Removing
– Carry out the function “Relieving pressure, gearbox hydraul‐
ics” ⇒ Vehicle diagnostic tester.
– Remove securing bolts -2- and pull cover -1- downwards out
of guide -arrow-.

– Separate connector -1-.

– Remove securing bolts -arrows-.
– Release wiring harness for gearbox hydraulic pump -V387- .

– Remove union nut from pressure line -1- on gearbox hydraulic

pump -V387- -3-.
– Pull suction line -2- off pan.
– Remove bolts -4- and remove gearbox hydraulic pump -
V387- .
Installing

Install in reverse order of removal, observing the following:

– Screw union nut for pressure line -1- hand-tight onto gearbox
hydraulic pump -V387- -3-.
– Push suction line -2- onto pan.
– Check level of hydraulic fluid and top up ⇒ page 35 .
Specified torque
Component Specified torque
Bolts for gearbox hydraulic 7.5 Nm
pump -V387- to gearbox hous‐
ing
Union nut for pressure line 16 Nm

1.13 Checking hydraulic fluid level

Special tools and workshop equipment required

1. Selector mechanism 35
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♦ Torque wrench -V.A.G 1331-

– Carry out the function “Relieving pressure, gearbox hydraul‐

ics” ⇒ Vehicle diagnostic tester.
When pressure has been relieved:
– Remove inspection plug -2- from pan -1-.
Catch any hydraulic fluid which may run out in a commercially
available container.

Note

♦ During normal operation, a small quantity of hydraulic fluid

may collect in tubes -2a- and -3a-, which will then escape when
the inspection plug -2- is removed.
♦ Filler plug -3- is not needed.

– Remove bolt -2- from securing clamp.

– Pull return hose -A- off connection pipe -1-.

Note

♦ When return hose -A- is pulled off, the sealing boot may remain
in the -hose-.
♦ Then pull the sealing boot out of the return hose -A- and push
the boot onto the connection pipe. -1-.

36 Rep. gr.34 - Controls, housing

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– Push a commercially available funnel into the pulled-off return

hose and add hydraulic fluid ⇒ Electronic parts catalogue
“ETKA” -arrow-.

– Add hydraulic fluid ⇒ Electronic parts catalogue “ETKA” until

it begins to run out through hole for fluid inspection plug -2-.
– Screw in inspection plug -2- with new seal.

Note

Specifications for hydraulic fluid ⇒ Maintenance ; Booklet 10.2 .

– Place return hose -A- on connecting pipe -1-.

– Screw in bolt -2- for securing clamp.
– Carry out the function “Learn gearbox shift position” ⇒ Vehicle
diagnostic tester.
Specified torque
Component Specified torque
Hydraulic fluid inspection plug 35 Nm
Hydraulic fluid filler plug 35 Nm

1.14 Draining and filling hydraulic fluid

Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

Draining
– Carry out the function “Relieving pressure, gearbox hydraul‐
ics” ⇒ Vehicle diagnostic tester.

1. Selector mechanism 37
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– Remove securing bolts -2- and pull cover -1- downwards out
of holder -arrow-.

– Separate connector -arrow-.

Note

Separating connector -arrow- will prevent unintentional starting of

hydraulic pump for gearbox -V387- .

– Remove hydraulic fluid filler plug -2- and hydraulic fluid drain
plug -1-.
Catch hydraulic fluid which may run out in a commercially avail‐
able container.
– Screw in hydraulic fluid filler plug -2- and hydraulic fluid drain
plug -1- with new seals -4- and -5-.
Filling

– Remove bolt -2- from securing clamp.

– Pull return hose -A- off connection pipe -1-.

Note

♦ When return hose -A- is pulled off, the sealing boot may remain
in the hose.
♦ Then pull the sealing boot out of the return hose -A- and push
the boot onto the connection pipe. -1-.

38 Rep. gr.34 - Controls, housing

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– Push a commercially available funnel into the pulled off return

hose -A- and add the specified quantity of hydraulic fluid -G
004 000- -arrow-.

Note

♦ Maintain the hydraulic fluid level exactly.

♦ Filling quantity 0.5 litre.
♦ Specifications for hydraulic fluid ⇒ Maintenance ; Booklet
10.2 .

– Place return hose -A- on connecting pipe -1-.

– Rejoin separated connector -arrow- for gearbox hydraulic

pump -V387- .
– Carry out the function “Learn gearbox shift position” ⇒ Vehicle
diagnostic tester.
– Separate connector -arrow- again.
– Unscrew inspection plug -3-.

– Pull return hose -A- off connection pipe -1-.

Note

♦ When return hose -A- is pulled off, the sealing boot may remain
in the hose.
♦ Then pull the sealing boot out of the return hose -A- and push
the boot onto the connection pipe. -1-.

1. Selector mechanism 39
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– Unscrew inspection plug -3-.

– Add hydraulic fluid ⇒ Electronic parts catalogue “ETKA” until
it begins to run out through hole for fluid inspection plug -3-.
– Screw in inspection plug -3- with new seal.

– Place return hose -A- on connecting pipe -1-.

– Screw in bolt -2- for securing clamp.

– Now rejoin separated connector -arrow- for gearbox hydraulic

pump -V387- .
– Then clear event memory entries ⇒ Vehicle diagnostic tester.
Specified torque
Component Specified torque
Hydraulic fluid inspection plug 35 Nm
Hydraulic fluid filler plug 35 Nm
Oil drain plug 35 Nm

40 Rep. gr.34 - Controls, housing

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 Crafter 2006 ➤
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2 Removing and installing gearbox

⇒ “2.1 Specified torques for gearbox”, page 41
⇒ “2.2 Removing gearbox”, page 41
⇒ “2.3 Installing gearbox”, page 45

2.1 Specified torques for gearbox

Specified torque
Component Specified torque
Bolt for gearbox housing to cyl‐ 38 Nm
inder block
Bolts for gearbox housing to 38 Nm
starter
Bolt for tachograph sender 10 Nm
Bolts for gearbox carrier at rear 45 Nm
of subframe
Bolts for gearbox support to 45 Nm
gearbox mounting
Bolts for exhaust pipe bracket 23 Nm
to gearbox

♦ Exhaust system; exhaust pipes and silencers ⇒ Rep. gr. 26 ;

Exhaust pipes/silencers .
♦ Propshaft, Assembly overview, propshaft ⇒ Rep. gr. 39 ;
Propshaft

2.2 Removing gearbox

Special tools and workshop equipment required
♦ Tensioning strap -T 10038-
♦ Engine support -T50015-
♦ Torque wrench -V.A.G 1331-
♦ Engine and gearbox jack -V.A.G 1383 A-

Removing
– Carry out the function “Relieving pressure, gearbox hydraul‐
ics” ⇒ Vehicle diagnostic tester.

41
2. Removing and installing gearbox
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Note

Cable retainers and clips which were removed or loosened must

be reinstalled in the same positions.

– Disconnect battery in interior ⇒ Electrical system; Rep. gr.

27 ; Battery; Disconnecting battery .
– Raise vehicle.
– Remove noise insulation from gearbox, if fitted.
– Unbolt propshaft -A- from gearbox flange and secure prop‐
shaft to body using e.g. baling wire.

– Loosen securing clamp on exhaust pipe -1-.

– Remove exhaust system in -direction of arrow- ⇒ Rep. gr.
26 ; Exhaust system .

Note

♦ Do not move exhaust filter, or the exhaust pipe will leak ⇒ Rep.
gr. 26 ; Exhaust system .
♦ Securing clamp -1- must always be renewed.

– Remove bracket -1- for exhaust system from gearbox.

42 Rep. gr.34 - Controls, housing

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– Unscrew bolt -3- for tachograph sender -G75- -2-.

– Always renew seal -1-.

Note

The tachograph sender -G75- is installed only in vehicles with a

tachograph.

– Separate connectors -1- and -2-.

– Unscrew bolts -2- at bottom of gearbox.

– Position engine and gearbox jack -V.A.G 1383 A- with gearbox

support -V.A.G 1359/2- under gearbox.
– Strap gearbox to engine and gearbox jack -V.A.G 1383 A- us‐
ing tensioning straps -T 10038- .
– Remove securing bolts for starter.

Note

Starter remains attached to engine.

2. Removing and installing gearbox 43

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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

– Unbolt bracket -3- and earth strap -4- from gearbox and tie it
out of way to side.
– Remove gearbox mounting ⇒ page 47 .
– Lower engine and gearbox jack -V.A.G 1383 A- with gearbox
support -V.A.G 1359/2- until the correct working position for
removing gearbox is attained.

– Attach engine strut -T50015- to available holes as shown in

figure -arrow-.

Note

♦ Depending on design, other components associated with op‐

tional equipment may be attached to the securing points for
the engine strut -T50015- .
♦ These additional components must be removed according to
the instructions in the respective workshop manuals.

– Turn spindle on engine strut -T50015- to bring engine to in‐

stallation position.

Caution

It is not permitted to support the engine between the sump and

the steering box.
This manner of support can lead to damage to the steering box.
As a consequence, hydraulic fluid leaks may develop in the
steering box, leading to the failure of power steering.
To avoid this, use engine strut -T50015- to support the engine
when removing the gearbox.

– Strap gearbox to engine and gearbox jack -V.A.G 1383 A- with

gearbox support -V.A.G 1359/2- using tensioning strap -T
10038- .

44 Rep. gr.34 - Controls, housing

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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

– Remove remaining upper bolts -1-.

– Carefully press gearbox from engine.
– Lower gearbox.

2.3 Installing gearbox

Installing
Install in reverse order of removal, observing the following:
– Clean input shaft splines and lightly grease with grease -G 000
100- .
The clutch plate must slide easily to and fro on the input shaft.

2. Removing and installing gearbox 45

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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

– Check whether dowel sleeves -A- for aligning engine and

gearbox are fitted in cylinder block and install if necessary
⇒ page 41 .

Note

If dowel sleeves -A- are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of gears
which are not engaged) could occur.

♦ All cable ties which were opened or cut during gearbox re‐
moval must be renewed at the same points when gearbox is
installed.
♦ If a tachograph is installed, the speed sensor for tachograph
must be sealed.

Note

A tachograph may be sealed only by an authorised and qualified

workshop.

– Set gearbox on engine and gearbox jack -V.A.G 1383 A- with

gearbox support -V.A.G 1359/2- and secure using tensioning
strap -T10038- .
– Align gearbox with engine and join.

Note

Do not remove engine and gearbox jack -V.A.G 1383 A- until

gearbox securing bolts are tightened to specified torques.

Further installation of the gearbox is carried out in the reverse

sequence.
– Check oil level in gearbox and top up if necessary
⇒ page 51 .
– Check hydraulic fluid level as appropriate ⇒ page 35 .
– Teach “gearbox selector positions” to gear detection sender -
G604- ⇒ Vehicle diagnostic tester.
Specified torques
♦ ⇒ “2.1 Specified torques for gearbox”, page 41
– Carry out road test.

46 Rep. gr.34 - Controls, housing

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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

3 Assembly mountings
⇒ “3.1 Removing and installing gearbox mounting”, page 47

3.1 Removing and installing gearbox

mounting
Special tools and workshop equipment required
♦ Engine and gearbox jack -V.A.G 1383 A-

♦ Torque wrench -V.A.G 1331-

Removing
– Position engine and gearbox jack -V.A.G 1383 A- with gearbox
support -V.A.G 1359/2- under gearbox.

3. Assembly mountings 47
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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

– Remove only bolts -2-.

Note

Depending on construction, there may be four securing bolts -2-

for the gearbox mounting.

– Now remove securing bolts -A- for gearbox mounting.

Installing
Install in reverse order of removal, observing the following:
Specified torque
Component Specified torque
Gearbox mounting to gearbox 30 Nm
carrier M8x20
Gearbox mounting to gearbox 45 Nm
M10x25

48 Rep. gr.34 - Controls, housing

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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

4 Gearbox housing, clutch housing

⇒ “4.1 Renewing sealing cover in gearbox housing”, page 49
⇒ “4.2 Removing and installing gearbox breather”, page 50

4.1 Renewing sealing cover in gearbox

housing
Special tools and workshop equipment required
♦ Fitting sleeve -3241/4-

♦ Oil seal extractor lever -VW 681-

Removing
– Remove Shiftmatic automated manual gearbox ⇒ page 41 .
– Remove slave cylinder with release bearing ⇒ page 5 .
– Pry out sealing cover -2- using oil seal extractor lever -VW
681- .
Installing
Install in reverse order of removal, observing the following:
Lightly coat sealing surface of sealing cover with oil.
– Drive in new sealing cover using thrust piece -3241/4- until
cover is flush with gearbox housing.
Continue installation in reverse order of removal:
– Check oil level in gearbox and top up ⇒ page 51 .
– Check hydraulic fluid level ⇒ page 35 .
Specified torques
♦ ⇒ “2.1 Specified torques for gearbox”, page 41

4. Gearbox housing, clutch housing 49

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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

4.2 Removing and installing gearbox

breather
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1783-

Gearbox breather
1- Breather housing with seal
2- Bolts
3- Bleeder hose
4- Gearbox filler plug
5- Gearbox drain plug
6- Breather connection
Specified torque
Component Specified torque
Breather housing bolt 6 Nm

50 Rep. gr.34 - Controls, housing

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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

5 Gearbox oil
⇒ “5.1 Checking gear oil level”, page 51
⇒ “5.2 Draining and filling gearbox oil”, page 52

5.1 Checking gear oil level

– Carry out the function “Relieving pressure, gearbox hydraul‐
ics” ⇒ Vehicle diagnostic tester.
– Remove securing bolts -2- and pull cover -1- downwards out
of guide -arrow-.

– Separate connector -1-.

Note

♦ Separating connector -1- will prevent unintentional starting of

hydraulic pump for gearbox -V387- .
♦ Connector -2- is not to be separated.

– Remove securing bolts -arrows- only from pressure accumu‐

lator and lay it to side.

5. Gearbox oil 51
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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

– To check final drive oil, remove oil filler plug -4-.

Correct oil level: 10 mm to lower edge of filler hole -1-.
To measure, use, for example, an Allen key.
– If necessary, top up gear oil.
Gear oil specification ⇒ Maintenance ; Booklet 10.2
– Screw in oil filler plug -1-.
– Attach pressure accumulator.
Specified torque
Component Specified torque
Oil filler plug 50 Nm

5.2 Draining and filling gearbox oil

Draining gear oil
– Remove securing bolts -2- and pull cover -1- downwards out
of guide -arrow-.

– Separate connector -1-.

Note

♦ Separating connector -1- will prevent unintentional starting of

hydraulic pump for gearbox -V387- .
♦ Connector -2- is not to be separated.

– Remove securing bolts -arrows- from pressure accumulator

and lay it to side.

52 Rep. gr.34 - Controls, housing

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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

– Remove oil filler plug -4- and oil drain plug -5-.
Catch gear oil which may run out in a commercially available con‐
tainer.
– After the gear oil has drained, screw oil drain plug in again
-5-.
Filling with gear oil
– Fill with gear oil.
Gear oil specification ⇒ Maintenance ; Booklet 10.2
Gearbox capacity 1.5 l.
The oil level is correct when the gearbox is filled to 10 mm below
the lower edge of filler hole -4-.

Note

To measure, use, for example, an Allen key.

– Screw in oil filler plug -4-.

Specified torque
Component Specified torque
Oil filler plug 50 Nm
Oil drain plug 60 Nm

5. Gearbox oil 53
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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

35 – Gears, shafts
1 Input shaft
⇒ “1.1 Renewing input shaft seal”, page 54

1.1 Renewing input shaft seal

Special tools and workshop equipment required
♦ Puller -T10055-

♦ Puller -T50012-

– Remove Shiftmatic automated manual gearbox ⇒ page 41 .

– Remove slave cylinder with release bearing ⇒ page 5 .
Removing
To pull out input shaft seal -1-, proceed as follows:

54 Rep. gr.35 - Gears, shafts

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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

– To pull out seal, screw sheet metal screw of about 4 mm di‐

ameter into seal -arrow-.
♦ Screw sheet metal screw in so that it jams between seal and
metal ring.

Note

Do not screw in sheet metal screw too far to avoid damaging

bearing behind it.

– Pull out seal -1- using puller -T10055- .

Installing

Install in reverse order of removal, observing the following:

Coat sealing lips of new seal with oil.
– Drive in new oil seal using thrust piece -T50012- until seal is
flush with gearbox housing.
– Check oil level in gearbox and top up ⇒ page 51 .
– Check hydraulic fluid level ⇒ page 35 .
Specified torques
♦ ⇒ “2.1 Specified torques for gearbox”, page 41
Component Specified torque
Securing bolts for slave cylin‐ 9 Nm
der with clutch release bearing

1. Input shaft 55
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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

2 Output shaft
⇒ “2.1 Renewing output shaft seal”, page 56

2.1 Renewing output shaft seal

Special tools and workshop equipment required
♦ Counterhold tool -3435-

♦ Thrust piece -T10089-

♦ Separating tool Kukko 17/2 not illustrated

♦ Counter support Kukko 22/2 not illustrated
Removing
– Unbolt propshaft -A- from gearbox flange and secure prop‐
shaft to body using e.g. “baling wire”.

56 Rep. gr.35 - Gears, shafts

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 Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012

– Unscrew securing nut -A- from propshaft flange.

– Set up pulling device as shown in figure and pull off propshaft.

A - Separating tool Kukko 17/2
B - Counter support Kukko 22/2
– Remove pulling device.
– Using, e.g., a screwdriver, pry out seal for output shaft.

Installing
Coat sealing lips of seal with oil.
– Drive in new oil seal using thrust piece -T10089- until seal is
flush with housing.

– Install propshaft flange and screw in securing nut -A-.

Continue installation in reverse order of removal.
Check gear oil level ⇒ page 51 .
Specified torque
Component Specified torque
Securing nut for propshaft 160 Nm
Propshaft to gearbox flange 15 Nm + 1/4 turn (90°) further

2. Output shaft 57
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