Car Fix DIY Videos

The gear module sensor on the Actros is defective and causes shifting trouble.
The sensor must be replaced. Remove the gear module.
Detach the gear module connector.
Detach the somewhat difficult to access air line.
Remove the 6 bolts and pull gear module out of its position.
The parts kit shown here is required.
Content: New gear sensor, cap, connector frame, 11 bolts, 2 O-rings, 2 seal, special lubricant.
To remove the connector frame release the 11 bolts and remove the frame.
Remove both bolts from the cap.
Unclip cover using suitable tool.
Remove gear sensor.
Remove seal from old connector frame. Do not use again!
New: The contacts for the new gear sensor are already greased.
The special grease prevents any fretting corrosion from occurring.
Place O-ring onto sensor and coat with lubricant from parts kit.
Insert new gear sensor. Observe correct installation position.
The cutout on the gear sensor must face towards the connector frame.
Unclip the two solenoid valves from their position and disconnect the intermediate plate.
The solenoid valves and intermediate plate are installed in the new connector.
Place a seal in the position of the housing and coat with lubricant.
Mount old intermediate plate onto new connector frame.
Insert solenoid valves.
Place second seal onto gear module housing and coat with grease.
Coat heads of solenoid valves.
Install new connector frame into gear module housing.
Screw in the 11 new bolts.
Tightening torque: 10 Nm.
Check position of sensor connector.
Slip O-ring over the cap and coat with lubricant.
Mount cover to gear module housing.
Check breather.
The one shown here is old and it has to be replaced.
Content of part kit: Rubber grommet, breather cap, clamp and sealing washer.
Remove old breather.
Insert new sealing washer into new clamp.
Mount both onto gear module.
Insert cap into rubber grommet.
Press both in to the clamp until they engage in place.
Clean surface of gear module housing thoroughly.
This is the only way of ensuring that the sealant works correctly.
Use spray gun to spray sealant generously onto the surfaces.
Install gear module with new sensor and cap into vehicle.
Teach-in transmission, then perform a short test drive.

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More Information:
Gear sensor part kit A 945 542 25 18
Breather part kit A 000 261 09 82
Sealant A 002 989 71 20 10
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