service information

Date: September/98 Distribution: II Substitues: Gr.: 58 Nr.: 04/98

Special Tools
New introductions:
Light Trucks - 712 C; 914 C
Heavy trucks - L/LS 1632; LS 1938; L/LK/LS 2638
Chassis for Bus - OF 1417

For your knowledge, enclosed herewith we are presenting the list of the Special Tools necessary to make the
maintenance and repair of the new aggregates applied in the above mentioned vehicles.

In order to facilitate, we have listed the tools by type of vehicle, that is:
• Annex I - Tools appointed to Light Trucks and Chassis for Buses.
• Annex II - Tools appointed to Heavy Trucks.

For the remaining aggregates, which application is being already made also in other vehicles, the tools previously
divulged are still valid.

Considering that several tools (see OBS. 2) do not appear yet in the “Catalogue A - Special Tools”, we recom-
mend that a copy of this S.I. be archived in the mentioned catalogue, after the separator Annexes.

MERCEDES-BENZ DO BRASIL S.A.

Service

MERCEDES-BENZ DO BRASIL S.A. REPRODUCTION OR TRANSLATION IN WHOLE

DIVISÃO ASSISTÊNCIA TÉCNICA OR IN PARTS IS NOT PERMITTED WITHOUT
WRITTEN AUTHORIZATION
 S.I. 58 - 04/98
Annex I
Page 01

SPECIAL TOOLS
LIGHT TRUCKS - 712C; 914C
NEW INTRODUCTIONS
CHASSIS FOR BUS - OF 1417

ENGINE OM 904
Nr. of Tool Gr./Class Denomination Obs.
904 589 00 07 00 01 B Claw-type spanner for the engine block protection bushing. 2
422 589 02 09 00 01A Dodecagonal socket, 19mm, for cylinder head screws. 2
000 589 17 21 00 01A Compression meter, 0 to 60 bar. 1
904 589 01 21 00 01A Adapter for compression meter. 2
98 904 589 00 61 00 01C Guide pin to position the sensing contact support, in the flywheel 2
frame.
904 589 01 63 00 01C Lifting device for engine cylinder head. 1
98 449 589 04 63 00 01C Device to disassemble and assemble the cylinder head with con- 1
stant engine brake throttle device.
98 904 589 00 63 00 01A Support to fasten the adapter Nr. 904 589 01 21 00 2
904 589 00 10 00 03B Multifanged spanner end, M14XZN, for flywheel screws. 2
904 589 01 10 00 03B Multifanged spanner end, M16XZN, for vibration damper screws. 2
904 589 02 15 00 03C Mandrel to install the seal in the crankshaft front cover. 2
904 589 03 15 00 03C Mandrel to install the seal in the rear valve timing box. 2
000 589 38 31 00 03C Compression band with ratchet for piston rings. 1
904 589 00 33 00 03C Puller for crankshaft front seal. 2
000 589 37 37 00 03C Universal pliers to install the piston rings. 1
904 589 02 63 00 03C Guide mandrel to disassemble the flywheel. 2
904 589 04 63 00 03B Device for turning the engine. 2
321 589 00 11 00 05D Long spanner, 17mm, for valves adjustment. 1
422 589 00 11 00 05D Idem, short. 1
904 589 02 14 00 05C Guide bushing to disassemble and assemble the camshaft.
103 589 03 15 00 05D Mandrel to remove the valve guides. 2
904 589 01 15 00 05D Idem, to install. 2
98 904 589 00 21 00 05D Gauge, Ø 8mm, for valve guides. 2
98 442 589 00 31 00 05C Valve puller. 2
98 904 589 00 31 00 05C Adapter for valve puller. 2
000 589 21 53 00 05D Manual reamer, Ø 7,99mm, for valve guides. 2
346 589 00 63 00 05C Cooling box for valve seats. 1
000 589 07 03 00 07A Open spanner, 17-19mm, for injection piping. 1
000 589 68 03 00 07A Special spanner, 17mm, for injection piping. 1
904 589 02 21 00 07A Minitester for diagnosis of electronic engines. 2
98 457 589 00 43 00 07A Puller for injector holder. 2
98 001 589 05 21 00 13A Belts tension meter. 1
904 589 03 63 00 13C Blocking device for the operation gear of air compressor. 2
98 904 589 00 23 00 18C Gauge to control the lubricating oil injection nozzles. 2
S.I. 58 - 04/98
Annex I
Page 02

360 589 00 15 00 20C Mandrel to install the seal in the water pump front cover. 1
98 001 589 06 21 00 20A Test device to check the cooling system tightness. 1

GEAR BOX ZF S5-420

Nr. of Tool Class Denomination Obs.
98 350 589 01 14 00 C Mandrel to install the seal and the oil scraper ring, in the shifter 1
coupling shaft.
710 589 01 15 00 C Mandrel to install the bushing in the shifter housing. 2
98 710 589 00 15 00 C Mandrel to install the seal in the rear cover. 2
98 710 589 01 15 00 C Mandrel to install the seal in the centering cover (drive shaft). 2
98 710 589 02 15 00 C Mandrel to install the drive shaft tension washer. 2
98 710 589 03 15 00 C Mandrel to install the center fork bearing. 2
98 710 589 04 15 00 C Mandrel to install the outer race of the main shaft and drive shaft 2
tapered roller bearing.
98 710 589 05 15 00 C Idem, for counter shaft. 2
717 589 00 31 00 B Immobilization wrench for coupling flange. 3
000 589 26 33 00 B Inner puller for shifter bushing and needle bearing of the housing 3
cover.
000 589 30 33 00 B Inner puller for tapered roller bearing outer race of the counter 3
shaft.
000 589 33 33 00 B Counter support, used together with 000 589 26 33 00. 3
000 589 34 33 00 B Counter support, used together with 000 589 30 33 00. 3
98 350 589 05 33 00 C Puller for the main shaft tapered roller bearing. 1
98 710 589 00 34 00 C Split ring for the main shaft tapered roller bearing (used together 2
with 98 350 589 05 33 00).
98 710 589 01 34 00 C Pulling support for the tapered roller bearing inner race of drive 2
shaft and main shaft (used together with 98 710 589 00 35 00).
98 710 589 02 34 00 C Idem, for counter shaft (used together with 98 710 589 00 35 00). 2
98 710 589 00 35 00 C Support plate for the tapered roller bearings inner race. 2
98 710 589 00 63 00 C Fastening support to disassemble and assemble the gear box. 2
98 710 589 01 63 00 C Support device to fasten the shafts assembly. 2
710 589 02 63 00 C Fastening support to position the selecting bar assembly. 2
710 589 03 63 00 C Pulling ring to remove the synchronization body and the 2nd speed 2
gear.
 S.I. 58 - 04/98
Annex I
Page 03

DISC BRAKE WABCO

Nr. of Tool Class Denomination Obs.
363 589 03 15 00 C Mandrel to remove the guide pin bushings. 1
98 688 589 02 15 00 C Mandrel to install the flanged screws. 2
98 688 589 03 15 00 C Mandrel to install the guide pin bushings. 2
98 688 589 04 15 00 C Mandrel to install the adjusting screw seal. 2
98 688 589 00 62 00 C Fork to remove the flanged screw covers. 2
98 688 589 06 63 00 C Support to install the adjusting screw seal cap. 2

STEERING BOX ZF 8090

Nr. of Tool Class Denomination Obs.
98 688 589 00 15 00 C Mandrel to install the bearings, in the gear box. 2
98 688 589 01 15 00 C Mandrel to install the steering worm seal, in the gear box. 2
98 682 589 00 21 00 C Device for sector shaft adjustment. 1
98 682 589 00 23 00 C Standard support to measure the distance from steering box sur- 1
face to bearing support surface.
98 345 589 00 31 00 D Fastening device for steering box. 1
98 345 589 04 33 00 B Puller for steering arm. 1
98 688 589 00 33 00 C Puller to remove the sector shaft bearings. 2
98 682 589 00 39 00 C Punch to redrive the sector shaft bearings. 1
343 589 00 40 00 C Dial gauge support to check the steering worm play. 1
98 682 589 00 61 00 C Guide bushing to install the seal, in the gear box. 1
98 682 589 06 63 00 D Fastening support, used together with 98 345 589 00 31 00. 1
98 688 589 00 63 00 C Adapter for sector shaft adjusting device, used together with 98 2
682 589 00 21 00.

OBSERVATIONS:
(1) - Tool already used in other aggregates.
(2) - New tool.
(3) - Tool belonging to group 00.
 S.I. 58 - 04/98
Annex II
Page 01

SPECIAL TOOLS
NEW INTRODUCTIONS - HEAVY TRUCKS L/LS 1632; LS 1938; L/LK/LS 2638

ENGINE OM 457
Nr. of Tool Gr./Class Denomination Obs.
904 589 00 07 00 01B Claw-type spanner for the engine block protection bushing. 2
422 589 00 09 00 01A Dodecagonal socket, 17mm, for engine cylinder head screws. 1
000 589 17 21 00 01A Compression meter, 0 to 60bar. 1
402 589 00 21 00 01C Measuring plate to give the initial pressure and measure the shoul- 1
der.
904 589 01 21 00 01A Adapter for compression meter. 2
98 449 589 00 33 00 01C Device to remove the cylinder liner. 1
98 449 589 01 33 00 01C Device to install the cylinder liner. 1
98 449 589 04 63 00 01C Device to install the cylinder head with engine brake constant 1
throttle.
98 457 589 01 63 00 01A Support to fasten the adapter 904 589 01 21 00 2
98 449 589 00 66 00 01C Milling cutter for cylinder liner seat, in the engine block. 1
422 589 02 09 00 03C Dodecagonal socket, 19mm with square hole 3/4”, for flywheel 2
and vibration damper screws.
98 457 589 01 15 00 03C Mandrel to install the seal in the crankshaft front cover. 2
98 457 589 02 15 00 03C Mandrel to remove the seal in the rear distribution box. 2
000 589 38 31 00 03C Compression band with ratchet for piston rings. 1
98 449 589 01 35 00 03D Device to remove and install the trapezoidal connecting rod bush- 1
ing.
000 589 37 37 00 03C Universal pliers to install the piston rings. 1
407 589 00 63 00 03B Device for turning the engine through the flywheel. 1
321 589 00 11 00 05D Long spanner, 17mm, for valves adjustment. 1
422 589 00 11 00 05D Short spanner, 17mm, for valves adjustment. 1
98 457 589 00 14 00 05C Guide bushing to disassemble and assemble the camshaft. 2
98 457 589 00 15 00 05D Mandrel to remove and install the valve guides and seats. 2
100 589 10 21 00 05D Gauge, Ø 12mm, for valve guides. 1
98 442 589 00 31 00 05C Valve puller. 2
98 457 589 00 31 00 05C Adapter for valve puller. 2
98 449 589 00 40 00 05C Dial gauge support, to check the distance between surfaces. 1
98 457 589 01 43 00 05B Mandrel to install the seal in the valve guides. 2
000 589 12 53 00 05D Manual reamer, Ø 11,99mm, for valve guides. 1
403 589 00 61 00 05B Guide bushing to install the seal in valve guides. 1
346 589 00 63 00 05C Cooling box for valve seats. 1
98 449 589 00 63 00 05C Device to fasten the cylinderhead. 1
000 589 07 03 00 07A Open spanner, 17-19mm, for injection piping. 1
000 589 68 03 00 07A Special spanner, 17mm, for injection piping. 1
904 589 02 21 00 07A Minitester for diagnosis of electronic engines. 2
98 457 589 00 43 00 07A Puller for injector holder. 2
98 001 589 05 21 00 13A Belts tension meter. 1
S.I. 58 - 04/98
Annex II
Page 02

98 457 589 00 63 00 13C Blocking device for the operation gear of air compressor. 2
98 457 589 00 23 00 18C Gauge to control the lubricating oil injection nozzles. 2
360 589 00 15 00 20C Mandrel to install the seal of the water pump front cover. 1
98 001 589 06 21 00 20C Test device to check the cooling system tightness. 1
98 449 589 00 21 00 20A Densimeter for cooling liquid. 1
98 355 589 00 34 00 20C Pulling support for the water pump hub. 1
98 355 589 02 43 00 20C Device to install the axle with bearing, in the housing. 1
98 355 589 03 43 00 20C Device to install the water pump hub and rotor. 1

GEAR BOX 16S-1650

Nr. of Tool Class Denomination Obs.
620 589 00 07 00 C Claw-type spanner for the main shaft spline nut. 1
620 589 01 14 00 C Guide bushing to install the shafts assembly, in the housing (used 1
together with 620 589 00 31 00).
98 350 589 01 14 00 C Bushing to install the seal and sealing element, in the shifting shaft 1
cover.
98 350 589 02 14 00 D Bushing to install the engaging rods seals of the planetary group. 1
343 589 00 15 00 C Mandrel with cone to install the speed indicator connection seal. 1
620 589 00 15 00 C Mandrel to install the rear cover seal. 1
98 350 589 05 15 00 D Mandrel to install the outer race of the counter shaft rear tapered 1
roller bearing.
98 370 589 04 15 00 C Mandrel to install the centering cover seal. 1
620 589 00 21 00 C Adjusting device for the shifting fork operation shaft, of multiplica- 1
tion group.
620 589 00 31 00 C Guide plate to install the shafts assembly, in the housing. 1
000 589 45 33 00 C Puller for the rear tapered roller bearing inner race, of counter 3
shaft.
98 345 589 11 33 00 C Puller for the front tapered roller bearing inner race, of counter 1
shaft.
98 620 589 01 34 00 C Puller support, used together with 98 345 589 11 33 00. 1
343 589 00 40 00 C Dial gauge support, used together with 000 589 59 63 00. 1
343 589 00 43 00 C Device to assemble the coupling flange. 1
620 589 00 59 00 C Lifting device to remove and install the shafts assembly, in the 1
housing.
98 620 589 00 61 00 C Guide bushing to install the cylinder with seal ring, in the selection 1
bar rods.
000 589 59 63 00 C Fastening chock for adjusting the counter shaft tapered roller bear- 1
ings.
620 589 00 63 00 C Device to install the drive shaft split ring. 1
98 350 589 10 63 00 C Adapter for device 343 589 00 43 00. 1
98 350 589 11 63 00 B Device to press the safety plate of the outlet flange screws. 1
98 620 589 00 63 00 C Device to install the main shaft split ring. 2
 S.I. 58 - 04/98
Annex II
Page 03

DISC BRAKE KNORR

Nr. of Tool Class Denomination Obs.
98 696 589 00 43 00 C Device to press the pressure piece with bellows, in the brake sad- 2
dle threaded tube.
98 696 589 01 43 00 C Device to install the inner bellow in the brake saddle seat. 2
98 696 589 02 43 00 C Puller to remove and install the brass bushing in the brake saddle 2
seat.
98 696 589 00 62 00 C Fork to remove the pressure pieces with bellow from brake saddle 2
threaded tube.
98 696 589 00 63 00 C Device to jump up the brass bushing in the brake saddle latch. 2

OBSERVATIONS:
(1) - Tool already used in other aggregates.
(2) - New tool.