Remove/install master control unit of torque converter clutch

AR25.40-W-0550A

Remove/install master control unit of torque converter clutch

13.11.08

 

Remove/install

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by jamming and burns when working on the engine while it is being started or when it is running

Secure vehicle to prevent it moving off.

Always wear appropriate work clothing when working on the vehicle.

AS00.00-Z-0005-01A

1

Drain oil at the oil drain screw (26) at the torque converter clutch housing and at the transmission

 Installation: Replace sealing rings on the oil drain screws (26).



*BA25.40-N-1017-01C



*BA26.40-N-1004-01D

2

Separate wiring harness (2) at torque converter lockup clutch pilot control valve (Y58)

 Observe installation position of plugs.

3

Remove master control unit (1) at torque converter clutch

 Installation: Plug the wiring harness (2) into the torque converter lockup clutch pilot control valve (Y58). Do not damage lines when installing the master control unit (1). Fit master control unit (1) to the converter lockup clutch using two parallel pins.



*BA25.40-N-1009-01C

4

Detach valve body (5) with the torque converter lockup clutch-pilot control valve (Y58) from master control unit (1)



*BA25.40-N-1006-01C

5

Detach torque converter lockup clutch pilot control valve (Y58) from valve body (5)

 Observe installation position of torque converter lockup clutch pilot control valve (Y58).

 Installation: Replace and grease O-rings (3, 4).



*BA25.40-N-1007-01C

6

Remove cover plate (7) with seals (6) at timing case (8)

 Installation: Replace seals (6).

 Danger!

Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension

Use only approved tensioning devices; shield off hazard area if necessary.
Inspect special tools for damage and proper operation (visual inspection).
Wear protective gloves.

AS00.00-Z-0001-01A

7

Remove cover (17) with seal (16)

 The cover (17) is spring-loaded, press the cover (18) against the timing case (8), then unscrew all bolts.

 Installation: Replace gasket (16); observe installation position of bolts.



*BA25.40-N-1008-01C

8

Remove compression springs (11, 15, 19, 21), ball (20), pistons (10, 13, 18) and bushes (14, 12) from timing case (8)

 Installation: Observe installation position of parts.

9

Remove screw plug (9)

 Installation: Replace sealing ring.



*BA25.40-N-1005-01C

10

Install in the reverse order

11

Check adjusted oil quality in Telligent servicing system and adjust the quality of the oil to be poured in if necessary

12

Remove oil filler screw (24) and inspection plug (25)

13

Pour in approx. 25 l of oil at opening of oil filler screw (24)



Gear oils (Sheet 235.12)

Sheet 235.12

BB00.40-P-0235-12A

14

Start engine and allow to run with the highest gear engaged

 Engage parking brake.

15

Pour in oil at the opening of the oil filler screw (24) until oil runs out at the check screw (25)

 Filling quantity depends on the version

approx. 25 to 40 l.

16

Screw in oil filler screw (24) and inspection plug (25)

 Install new sealing rings.



*BA25.40-N-1017-01C



*BA26.40-N-1011-01D

17

Shift the manual transmission into neutral, allow the engine to run for 2 to 3 minutes at approx. 1200 rpm

 This is necessary so that the heat exchanger, oil reservoir and oil lines can be filled completely with oil.

18

Inspect transmission oil level, adjust to correct level if necessary

AR26.00-W-0100C

19

Check master control unit (1) for leaks

 Visual inspection.

Number

Designation

Engine 541.9, 542.9
with code G02

BA25.40-N-1005-01C

Screw plug to master control unit

M121.5

Nm

35

BA25.40-N-1006-01C

Bolt, valve body to master control unit

Nm

10

BA25.40-N-1007-01C

Bolt, solenoid valve to valve body/master control unit

Nm

5

BA25.40-N-1008-01C

Bolt, cover to timing case

M612

Nm

10

M618

Nm

15

BA25.40-N-1009-01C

Bolt, master control unit to torque converter clutch housing

Nm

25

BA25.40-N-1017-01C

Screw plug to torque converter clutch

M241.5

Nm

50

M261.5

Nm

65

Number

Designation

Transmission 715.500/507/
510/513/517/
520/527/540

BA26.40-N-1004-01D

Oil drain screw to transmission housing

Nm

60

BA26.40-N-1011-01D

Oil filler screw/oil check screw to transmission housing

Nm

60