Professional Documents
Culture Documents
ARS TECHNICA
Technische Informationen für den Betrieb
und die Wartung und Reparatur der Marke
Mercedes Benz Type 404,0 & 404,1 UNIMOG
Jahre 1955 –1980
This technical data file contains operations, service and repair information for the Mercedes Benz Unimog
type 404 built from 1955 to 1980 in the following types:
1972-1980
404.010 / U82 / M180.958 / Open Cab
404.011 / U82 / M180.958 / Closed Cab
404.012 / U110 / M130.925 / Open Cab
404.013 / U110 / M130.925 / Closed Cab
1955-1977
404.111 / U80 / M180 / Open Cab
404.112 / U80 / M180 / Closed Cab
404.113 / U82 / M180 / Open Cab/Closed Cab
404.114 / U82 / M180 / Open Cab/Closed Cab
404.115 / U82 / M180 / Open Cab/Closed Cab
404.117 / U60 / OM615 / Open Cab
Thank you for downloading the Ars Technica Electrographics Technical Data File for the
Mercedes Benz Unimog Type 404. A lot of care has gone into formatting this document to
provide the highest possible ease of use, readability and portability. Much of the informa-
tion provided herein has been available from other sources but not as a packaged and
printable PDF file.
Ars Technica Electrographics 28 Main Street Accord New York 12404
845.853.6392 / 845.626.2898
Section 1 - Unimog Type 404 Glove Box Manual
ARS TECHNICA
ELECTROGRAPHICS
Section 2- Unimog Type 404 Workshop Manual
ARS TECHNICA
ELECTROGRAPHICS
Workshop Manual Unimog 404
Group 000, Technical Data
Sub Group 0-1, Model & Data
Sub Group 0-2, Engine
Sub Group 0-3, Chassis 404.1
Sub Group 0-3.1, Chassis 404.0
Sub Group 0-4, Tightening Torques 404.1
Sub Group 0-4.1, Tightening Torques 404.0
Group 001, Engine Housing
Sub Group 1-1, Cylinder Head
Sub Group 1-2, Valve Guides
Sub Group 1-3, Valve Seats
Sub Group 1-4, Boring & Honing Cylinders
Group 003, Crank Assembly
Sub Group 3-1, Crankshaft
Sub Group 3-2, Crankshaft Bearings
Sub Group 3-3, Connecting Rods
Sub Group 3-4, Pistons & Rings
Sub Group 3-5, Flywheel
Sub Group 3-6, Balancing
Group 005, Engine Timing
Sub Group 5-1, Rocker Arm Bearings
Sub Group 5-2, Valves
Sub Group 5-3, Valve Clearance
Sub Group 5-4, Timing Gears & Intermediate Shaft
Sub Group 5-5, Camshaft & Bearings
Sub Group 5-6, Chain Tensioner
Sub Group 5-7. Timing Chain & Side Rails
Group 007, Carburetor & Injection System
Sub Group 7-0, Testing, Measuring & Adjustments
Sub Group 7-2, Carburetion System
Sub Group 7-5, Ignition System
Page 1 of 5
Workshop Manual Unimog 404
(continued)
Page 2 of 5
Workshop Manual Unimog 404
(continued)
Page 3 of 5
Workshop Manual Unimog 404
(continued)
Page 4 of 5
Workshop Manual Unimog 404
(continued)
Page 5 of 5
METRIC CONVERSION FACTORS
(Symbols of SI units, multiples and submultiples are
given in parentheses in the right-hand column)
Multiply By To Obtain
LENGTH
centimeter 0.03280840 foot
centimeter 0.3937008 inch
TEMPERATURE
To Convert Form To Use Formula
Temperature Celsius, tC Temperature Kelvin, tK tK=tC+273.15
Temperature Fahrenheit, tF Temperature Kelvin, tK tK=[tF+459.67]/1.8
Temperature Celsius, tC Temperature Fahrenheit, tF tF=1.8 tC+32
Temperature Fahrenheit, tF Temperature Celsius, tC tC=[tF-32]/1.8
Temperature Kelvin, tK Temperature Celsius, tC tC=tK-273.15
Temperature Kelvin, tK Temperature Fahrenheit, tF tF=1.8 tK-459.67
Temperature Kelvin, tK Temperature Rankine, tR tR=9/5 tK
Temperature Rankine, tR Temperature Kelvin, tK tK=5/9 tR
ARS TECHNICA
ELECTROGRAPHICS
Modification of the UG1/11 transmission from the
U 404 S from 6- to 8 forward speeds.
Introduction:
UG stands for Unimog Getriebe and the UG1/11 found in the ‘404 S’ is the same as installed in
the early Boeringer and 411’s mogs, with some little changes and improvements over the time.
The original design is still in all the transmissions from the U 4xx.xxx series, from the first
unsynchronized UG1/11 to the synchromesh over the UG2/27 to the UG2/30 with a lot of
combinations for PTO, sideway power take off and winches, splitters, creeper gears,
hydraulic and air operated systems. The basic modular design is well thought, so the original
idea is valid for over 55 years now with only mayor changes and developments in the brass
bushings, bearings, the shift plate and that they now operate with some air cylinders.
A quick look to the 3 issues of transmissions let you recognize, that the transmission housing
is still the same, but with some additional bores & mounting points, later with stronger gears -
but the same basic size. You can find this transmission housing in their corresponding Mog
models from the 70200, 2010, 401, 402, 403, 411, 404, 421, (406):
basic 1x6 shift plate speed 2x4 shift plate(U406) shift plate (U419, SEE)
To know really about all possible combinations, you have to think about a serious study of this
topic. There where also special designs for the customer needs and military applications.
Researching for information:
To find info about the 404S ‘Mog’ transmission today is
difficult, especially for our old UG1/11 tranny. Thanks to the
list members from RMM, Mog4x4 and MogTech, I was able
to collect sufficient info from manuals, images, e-mails,
photos and scanned material to see, that due to the basic,
modular design of the transmission, especially the housing
and the shift plate, it should be possible to modify the
UG1/11 to work like the transmissions found in the U421 and
U406/416 with 8 forward speeds: 4 in the low range and 4 in
Searching for info with
the high range. Here where I live in Venezuela is no ‘mog’ all imaginable sources …....
with a 2x4 transmission around, so it was a detective like
work to see what the mayor differences between the ‘trannies’ are and what they have in
common, looking only on the material collected as the source for technical information. But
relatively quickly it was clear, that the mod is possible without touching the gears or shift
forks inside the transmission. The clue is in the shift plate and the shift cover plate in both
models. After understanding the differences, it was obvious that the old Q- shifting
( “Q = Querschalten” = traverse shifting) has to be substituted with an additional lever.
If you like to keep your Mog original, find you a shift cover with levers
and a shift plate from a spare or toasted U404 tranny sitting around. If
you can get those parts from a 2x4 tranny, for example from a 421 or
406 transmission, then you have found the best shortcut. With the
404S material, you need to find or fabricate the additional lever for the
high/low range selection. The transmission housings are basically the
same.
An overhauled UG2/27 (with PTO) …….. you recognize the family ……..
You need a
shift cover…
… and a shift
plate.
The theoretical part of the modification: The shift plate
Looking now at some pictures with good detail let you quick understand what is to do here:
This is an original 6 speed shift plate found in 411, 404, 421 and 406(?) in their basic setup.
The group of parts that conforms the simple “ shift logic “ , items # 11,12,13,14,15 and 16 are
not on the 2x4 shift plate. These parts will be taken apart for the conversion, among others.
The angular lever (#13) is actuated when shifting “ Q-traverse “ in to low gears (1 & 2) and
this unlocks the two reverse gears too. But this also blocks our additional two low gears that
we want .
There is one minor difference on this plate, it is the little slot above the #13 (arrowed
yellow), this could be used to shift the high/low range where it is already present if you have
this version of the plate from a newer (2x4) transmission and the lever with the longer
finger. If this is your case, you need to make a lever with aprox. an 80mm long finger.
For the conversion starting from a 404 (UG1) tranny there is another easy solution. The red
arrow on both images (pages 5 & 6) points to the part where on the other side is the shift
fork located for the selection of the high and low range.
The blue arrow points to a small 60mm x 30mm (3mm thick piece of metal) welded on to the
plate; that eliminates the old 1st and 2nd gear lever positions from the 1x6 plate.
This is already the 2x4 plate and do not use that third part of the ‘double “H” slot for
shifting.
Here is another older image from an earlier shift plate (again with minor differences that
Gaggenau changed later, - did you see them ? ) that shows very good the two shift variants:
First the 1x6 speed, below there is the 2x4 speed shift plate.
Now, let’s look to the next involved component of the transmission mod : The main cover.
Here you have to keep in mind, as “ a reminder “, that with the modification in the way I did
it, you can not use a PTO from a UG1/11 (404S) when driving with the 8 speed modified
transmission, because I took the place for the PTO lever for the high/low range shift lever
and put the long shift fork out of the way. That is why I still keep a set of a transmission
cover and an unmodified original shift plate as a spare, so I can return to the original setup if
I want or if needed some day. You can use a PTO from a U421 or similar after the mod, but
this is to be checked out first, but it really looks do-able.
Most of the modification is to be done here on the shift plate, and consists more or less in
taking pieces away .
The angle lever for the ‘Q’ – shifting of the high /low range in the 1st and 2nd gears forward
and reverse, the flat holder, the frame with all its components and the slider plate- are not
needed. You can save them as spares (or elaborate a trophy for the next NWMF ……? ).
A quick sidekick in to the gearbox:
Here I put two similar images together, the left one is a UG1/11 tranny from a 404, the right
one is a UG2/27 from a 416:
You can observe (again) that the two transmissions share the same housing, the eye catching
difference is, that the gears from the UG2/27 are stronger (thicker and have a little lesser
teeth), also you can see how the torque transmission goes from the right to the left, from
“thinner” gears and with more teeth to the ‘heavy’ ones on the right. The original design is
still in all transmissions: A drive shaft (input from the engine/clutch) and three shafts with
the gears (pre stage shaft, counter shaft and the main shaft)
Note the lateral power take off with a big pulley for belts or
hydraulic pumps and the early type shift covers…
Take the main cover: For easier manipulating, put the long main lever
apart. On the underside, take the coil spring of the detent (safety
lockers, spring retainer, roller guide and two small rollers out. See the
manual page. 26.4.4.4.).
There are two big rivets that hold the sliders for
the shift fork of the PTO gear. Put the main cover
on the work bench or in a grip (holding it on the shift
fork). On the top, punch mark the two rivets
(centered) and drill with a 4mm or similar diameter
about 10mm deep.
Then, with a 10mm or 11mm bore drill careful until the top of the rivet begins to spin, or you
feel that it becomes loose. Take care not to drop the main cover when the last rivet comes
out. Take apart the shift fork, the guide pieces and followers. Save the fork to fabricate
some parts with it later.
Forward
direction
This is an original from a U421 from Gaggenau This one is an ‘user’ modified from a U404
A new decal must be made for……… let’s baptize the creature: “ OctoTran “ (?)
Legend:
………well, everybody could be creative now and design his decal to the individual tastes.
Important: Before shifting from high in to low range, stop the vehicle (as usual). Shifting
from the low range in to the high range can be done while driving normally.
Third : The new (additional) shift lever:
This is the item which demands the most work, believe it or not. Those with luck who found a
main cover and a shift plate from a U421 or U406 can finish the mod at once, only swap the
two parts. Before taking apart the cover and plate from the 404, shift in to neutral and
forward position. Change the levers on the exchange cover and
plate to the same positions and the high/low range lever to the
high range. Swap the parts, bolt on and you’re done. The
procedure is described in the (original) MB shop manual.
… this way …
Now make a lever modifying a spare lever or bend something (Φ 9mm) useful into shape:
(Sorry, no more real pics (no Mog nearby) – the Mog is sold).
This is the lever & finger assy,
If you have a shop, you perhaps want to fabricate this part from scratch (new) and mill a
piece of steel, sure more elegant. (This one is only an example). I’m using up some of the left
over parts and material from the modified shifting cover and trying to keep the things simple
and easy!
The (useless) pinion of the PTO is to be limited from moving backwards with a little weld
point or a punch on the shaft with a chisel, so it could not slide and not touch the housing.
(Arrowed red)
Some other earlier pictures from the shift plate during the work:
My “tranny” simulator
I hope this could be a little guide of one of the possible ways to realize the
tranny modification to enjoy the (two more) four off road gears.
This is not the only way to do it. Sure there is even a better one.
But, perhaps I could infect some of you 404 owners with the defiance
to do another mod?
This conception is dedicated to all Moggers from the mog list. Feel free to comment and to
drop me a line if you like (bekawe@gmail.com) . Than’X
July, @ 2007
Section 4– Mercedes Benz M180 Overhaul Manual
ARS TECHNICA
ELECTROGRAPHICS
Table 1 – Front Axle – Group 01
Item # Part # Mod. # Item Description footnotes All 113 114 115 117
- 01.4041.0113-00 replaced by 404 330 02 99 -
- 01.4041.0116-00 replaced by 404 330 02 99 -
39 01.2010.1049-00 Race 1
49 01.2010.1200-00 Shaft* 1
53 01.4111.1028-00 Cover 1
61 01.4111.1023-00 Gasket* 1
82 01.2010.1010-00 Gasket 2
13 01.4041.1067-00 Link 2
14 99.2939.1008-00 Pin 4
Brake Lines
40 000 429 04 37 Distributor 1
44 01.4041.0768-00 dto 2 1
- 000 428 00 72 Pipe Union Nut 2
45 01.4041.0769-00 dto 2 1
- 99.2905.1005-01 dto* nB
- 99.2905.1005-02 dto* nB
21 01.2010.1153-00 Boot 1
22 99.2937.1001-00 Plug 4
39 01.2010.1049-00 Race 1
49 01.2010.1200-00 Shaft* 1
52 01.4111.1028-00 Cover 1
84 01.2010.1010-00 Gasket 2
21 99.2939.1008-00 Pin 4
Brake Lines
- 02.4041.0715-00 Pipe Line. Left 9 1
5 Up to chassis 7502329
7 Up to chassis 042318
9 Up to chassis 8501400
1 No longer available
27 05.4111.1014-00 Retainer 2
65 06.4041.0711-00 Bracket 4 1 1 1
66 31.2010.1022-00 Clamp 1 1 1
1 Up to Chassis 85 01400
2 From Chassis 85 01401
3 Up to Chassis 75 02329
2 07.2010.1004-00 Bushing 1 1 1
- 07.2010.1013-00 Pawl 1 1 1 1
14 07.4111.1005-00 Pawl 2 1 1 1
15 07.2010.1014-00 Screw 1 1 1
16 000439 008200 Nut 1 1 1
- 99.2981.1003-00 Spring 1 1 1 1
17 07.4111.1006-00 Spring 2 1 1 1
1 Up to Chassis 75 02329
4 Up to Steering 6501049
6 Up to Steering 8500704
30 07.2010.1014-00 Screw 1
41 10.4041.1009-00 Lever 1 1 1
3 Up to Chassis 011664
Table 17 – Differential Linkage – Group 11
Item # Part # Mod. # Item Description footnotes All 113 114 115 117
1 11.2010.0804-00 Spring Link 2
10 99.2981.1001-00 Spring 1
5 13.2010.0915-00 Countershaft 1
29 13.4041.1010-00 Follower 1
38 99.2954.1010-00 Shim 1
- 99.2955.1007-00 Replaced By - - -
- 99.2955.1007-01 411 991 XX 35 Series
- 99.2955.1007-02
- 99.2955.1007-03
- 99.2955.1007-04
- 99.2955.1007-05
- 99.2955.1007-06
- 99.2955.1007-07
- 99.2955.1007-08
- 99.2955.1007-11
- 99.2955.1007-12
- 99.2955.1007-13
- 99.2955.1007-14
- 99.2955.1007-15
- 99.2955.1007-16
- 99.2955.1007-17
50 13.4041.1013-00 Shaft 1
8 99.2939.1002-00 Clinch-Bolt 1
20 13.2010.0768-00 Latch 1
28 13.2010.0784-00 Follower 1
32 13.2010.1602-00 Guide 4
35 99.2980.1021-00 Spring 2
36 99.2980.1022-00 Spring 2
39 13.2010.1309-00 Follower 1
41 13.2010.1074-00 Guide 3
57 13.2010.1324-00 Guide 1
59 13.2010.1601-00 Guide 1
63 99.2980.1021-00 Spring 1
71 13.4041.1061-00 Lever 1
74 13.4041.1037-00 Cover 3 1 1 1
82 13.4041.1043-00 Lever 1
87 13.4041.1046-00 Cover 1
1 Up to Transmission 9501587
3 Up to Transmission 9502750
5 Up to Transmission 9503499
7 Up to Transmission 9503549
9 Up to Transmission 017172
11 Up to Transmission 033180
- 29.4041.0702-00 Bracket 1 1
- 29.4041.1004-00 Shim 1 1 1 1
1 Up to Chassis 85 02850
Table 21 – Fuel System – Group 31
Item # Part # Mod. # Item Description footnotes All 113 114 115 117
1 31.4041.0808-00 Fuel Tank 1 1 1
70 64.2010.1008-00 Spacer 1 1 1
16 32.4041.1009-00 Shackle 1
17 32.4041.1013-00 Console 1
24 32.4041.0714-00 Bracket 3 1
- 32.4041.1040-00 Clamp 2 1 1
28 32.4041.1033-00 Clamp 1
29 32.4041.1034-00 Clamp 2
30 32.4041.0713-00 Clamp 1
3 Up to Chassis 8500100
22 35.4041.1006-00 Shackle 2 2 2
23 35.4041.1009-00 Pin 2 2 2
38 99.2901.1010-00 Washer 1
1 Up to Transmission 017172
3 40.2010.1033-00 Cup 2 2 2
6 40.2010.1034-00 Washer 2 2 2
- 40.4041.0713-00 Bracket 1 1 1 1
12 40.2010.1017-00 Clamp 1 1 1
13 40.2010.1018-00 Clamp 1 1 1
14 40.2010.1030-00 Washer 3 2 2 2
4 4 4 4
28 40.4041.1019-00 Clamp 1 1 1
3 40.2010.1033-00 Cup 2
5 40.2010.1034-00 Washer 2
9 40.2010.1017-00 Clamp 2
10 40.2010.1030-00 Washer 4
46 31.2010.1022-00 Clamp 1
1 Up to Chassis 050568
3 Up to Chassis
4 From Chassis
Table 27 – Batteries – Group 60
Item # Part # Mod. # Item Description footnotes All 113 114 115 117
1 072311 012003 Battery 12V/ 56 Ah 2
12 67.4041.0734-00 Frame 1
13 67.4041.1085-00 Support 1
- 67.4041.1086-00 Support 2 2
14 67.4041.1112-00 Support 2
36 60.2010.1017-00 Boot 3 3 3
37 315 540 00 43 Cable Connector 15 1 1
41 60.4041.1179-00 Boot 15 1 1
- 60.2010.1031-00 Grommet 1 1 1 1
1 Up to Chassis 032520
3 Up to Chassis 044794
5 Up to Chassis 049678
7 Up to Chassis 053197
14 Up to Chassis 75 02329
16 Up to Chassis 9500924
20 Up to Chassis 6501165
22 Up to Chassis 043113
23 Up to Chassis 6500499
25 Up to Chassis 024243
27 Up to Chassis 9502535
29 Up to Chassis
30 From Chassis
31 Up to Chassis 023332
33 Up to Chassis 9501178
39 Up to Chassis 044431
11 62.4041.1090-00 Spring 1 1 1
62 62.2010.1104-00 Handle 3 2 2 2
98 62.4111.0618-00 Cover 1 1 1
1 Up to Chassis 6500749
3 Up to Chassis 7502329
5 Up to Chassis 8500204
8 Up to Chassis 039300
10 Up to Chassis 042633
12 Up to Cab 133
14 Up to Chassis
15 From Chassis
16 See Service Information
18 Up to Chassis 053136
20 Up to Chassis 052283
- 65.4041.0704-00 Hinge 5 8 8
3 65.4041.0608-00 Hinge 6 8 8 8
9 65.4041.1205-00 Washer 11 2 2 2
25 65.4041.1303-00 Bracket 2 2 2
35 65.4041.0743-00 Shackle 3 3 3
47 65.4041.1232-00 U-Bolt 15 2 2
48 65.4041.1233-00 Washer 15 2 2
- 65.4041.1205-00 Washer 11 2 2 2
3 69.4041.0725-00 Damper 1 1 1
3 Up to Chassis 6501165
5 Up to Chassis 7502329
7 Up to Chassis 9501178
9 Up to Chassis 8502255
10 From Chassis 8502256
14 For Platforms 404 600 00 03, 404 600 01 03 and 404 600 02 03
9 70.4041.1132-00 Washer 2 2 2
11 70.4041.1122-00 Tube 2 2 2
12 70.4041.1123-00 Tube 2 1 1
5 Up to Chassis 040367
37 99.2901.1022-00 Washer 4 1 1 1
Washer 5 2 2 2
Washer 2
40 90.4041.0703-00 Chock 1 2 1 1
42 91.4041.1059-00 Shoe 1 2 1 1
4 Up to Chassis
5 From Chassis
6 On Models 113, 115 Up to Chassis 049678 Left & Right Parts Replaceable Together ONLY.
On Models 114 Up to Chassis 049740 Left & Right Parts Replaceable Together ONLY.
7 On Models 113, 115 Up to Chassis 049678
On Models 114 Up to Chassis 049740
8 Up to Chassis
9 From Chassis
Section 5– Mercedes Benz M130 Overhaul Manual
ARS TECHNICA
ELECTROGRAPHICS
Table 00 – Engine M180 – Group 01
Fig. # Part Number Mod. # Item Description footnotes All 952 953 958
Oil Pan
Valve Cover
Crankshaft Bearings
Connecting Rods
Pistons
Rocker Arm
76 41.4041.0708-00 Elbow 1 1
77 41.4041.1031-00 Grommet 1 1
Exhaust Manifold
Generator
27 30.4041.1107-00 Pulley 1 1
42 30.4041.0701-00 Frame 1 1
43 130 150 09 73 Frame 1
Spark Plugs
Water Outlet
61 30.4041.1063-00 Hub 1 1
62 30.4041.1064-00 Race 1
- 30.4041.1064-00 Race 1 1
89 30.4041.1074-00 Gasket 2 2
5 Applicable to 404.113.
ARS TECHNICA
ELECTROGRAPHICS
Table 00 – Engine M130 – Group 01
Fig. # Part Number Mod. # Item Description footnotes All 922 925
- - - Crankshaft Bearings - - - -
- - - Connecting Rods - - - -
- - - Pistons - - - -
- - - Valves - - - -
- - - Rocker Arm - - - -
12 41.4041.1031-00 Grommet 1
- - - Intake Ducting - - - -
- - - Exhaust Manifold - - - -
52 30.4041.0713-00 Frame 1
55 30.4041.1083-00 Support 1
- - - Water Outlet - - - -
47 404 200 04 56 Water Cooling Outlet 1
56 30.4041.1063-00 Hub 1
58 30.4041.1064-00 Race 1
79 30.4041.1074-00 Gasket 2
3 On Model 922
4 On Model 922
12 On Model 922, From Engine 000057. Use up all old stock before issuing new parts
Section 7– Unimog Type 404 Winch Manual
ARS TECHNICA
ELECTROGRAPHICS
Section 8– Unimog Type 404 Technical Illustrations
ARS TECHNICA
ELECTROGRAPHICS
Ars Technica Electrographics was founded in 2005 on the principle of providing quality technical
illustrations & documentation with high accuracy and attention to detail Using modern software
in conjunction with the vision of classical hand drafting Ars Technica Electrographics can provide
two dimensional drawings in ANSI Sheet A through D as well as digital media. Additionally Ars
Technica Electrographics can provided three dimensional modeling and rendering services
ranging from simple sheet and shell models to concise engineered assemblies. Machine ready
images for use with CNC cutting & milling tools is also available by arrangement.
Ars Technica Electrographics also supports the Mercedes Benz line of Unimog trucks. Do you
need to build FOPS/ROPS systems? Do you need to design a camper cabin? Technical and
material support for lighting? Self recovery electric and hydraulic winching systems? Ars
Technica Electrographics can provide support ranging from design review, information sup-
port, technical education and complete drafting and design services.
Contact Ars Technica Electrographics today to discuss how we can help you reach you goals.
Francis Taracido
Ars Technica Electrographics
28 Main Street
Accord NY 12404
845.853.6392
845.626.2898
ARS TECHNICA
ELECTROGRAPHICS