720S

CAUTION!
Risk of foreign material entering the transmission! Damage may occur to the transmission internal components. Clean the transmission and your work area before you begin the procedure.

CAUTION!
Risk of foreign material entering the transmission! Damage may occur to transmission internal components. Clean the transmission and your work area before you begin the procedure.

CAUTION!
Risk of repeating the actuator alignment process! Incorrectly aligned actuators may cause the transmission to malfunction. Make sure the actuators do not move when removing the alignment tools.

CAUTION!
Risk of transmission fluid loss! Fluid loss may cause the transmission to malfunction. Clean the mating faces using a plastic scraper.

CAUTION!
Risk of transmission malfunction! Incorrectly aligned actuators may cause the transmission to malfunction. Make sure the actuator alignment procedure is correctly followed.

Care Point:

The transmission must be removed. Add the transmission labour time to this repair time to get the total.

Care Point:

A ball ended 5mm Allen socket is required.

Remove

1.	Remove the transmission.
2.	Record the SAV serial number (1).

3.	Disconnect the electrical connectors from the SAV (2).
4.	Remove the 8 bolts (M6 x 30mm) (3).

Care Point:

A ball ended 5mm Allen socket is required to remove the two bolts near the electrical connector.

Remove the 8 bolts (M6 x 22mm) (4).

Remove the SAV from the transmission.

Care Point:

Use the plugs supplied with the replacement SAV.

Install the 2 plastic plugs to seal the SAV (5).

Put the SAV in a new plastic bag, seal the plastic bag to prevent hydraulic fluid from spilling.

Care Point:

One gear selector fork is shown, the other 3 are similar.

Check the position of the gear selector forks, the gear selector forks should be in the neutral position. The detent (6) must be engaged in the position shown.

10.

Install a clean cloth (7) to prevent contamination of the transmission.

11.

Remove and discard the 2 dowels (8).

12.

Remove and discard the gasket (9).

13.

Remove any gasket material that remains on the mating surface.

Install

1.	Remove the new SAV from the packaging , record the new SAV serial number.
2.	Remove the 2 plastic plugs from the SAV (10)

Care Point:

It may be necessary to push the actuators in the direction shown to install the tools.

Install the 2 alignment tools (11), the alignment tools must engage in the recess on each actuator.

4.	Push the 2 actuators in the direction shown, the alignment tools must stop against the actuator and the actuator housing.
5.	Install the alignment tool (12) in the position shown, hold the alignment tool (12) against the outer actuators.

Care Point:

Make sure the alignment tools on the 2 outer actuators remain engaged.

Push the 4 actuators against the alignment tool.

Remove the alignment tools from the SAV.

Install the 2 new dowels

Install the 2 SAV guide tools (13).

10.

Install a new SAV gasket (14), the gasket must align with the 2 dowels.

11.	Remove the cloth installed to prevent contamination (15).
12.	Install the new SAV, make sure the mating faces touch the gasket.
13.	Apply Loctite 242 to the 16 SAV bolts.

Care Point:

A ball ended 5mm Allen socket is required to tighten the 2 bolts near the electrical connector.

14.

Install the 8 bolts (16) (M6 x 30mm).

15.

Tighten the 16 bolts to 3Nm in the sequence shown.

16.	Tighten the 16 bolts to 10Nm in the sequence shown.
17.	Connect the 2 electrical connectors (18) to the SAV.
18.	Install the transmission.

V. 3.9

Note