Remove/install transmission with torque converter · ar2710p0500p · Mercedes-Benz WIS

AR27.10-P-0500P

Remove/install transmission with torque converter

06.03.2020

Transmission	722.6 in model 203 (except 203.02/05/08/09/22/25/28/29), 209
Transmission	722.9 in model 203.052/054/056/252/254/256/752/756, 209.354/356/372/376/454/456/472/476

Remove/install transmission with torque converter

P27.10-2095-09

Shown on model 203 with transmission 722.6

2	Bolts	20	Ground cable	63	Shift rod
4	Oil pan drain screw	21	Pipeline	63a	Fuse
12	Rear engine cross member	49	Oil cooling line	95	Screw
13	Exhaust bracket	50	Oil cooling line	A	Engine 111.955
17	Front propeller shaft	50a	Screw	B	Except engine 111.955

Topical note	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
 	Remove/install
1	Detach ground line from battery	MODEL 203	AR54.10-P-0003P
Topical note	Notes on battery		AH54.10-P-0001-01A
		MODEL 209	AR54.10-P-0003Q
2.1	Remove air filter	ENGINE 111, 112
		 Installation: Lightly grease the rubber guides to make assembly easier.
2.2	Remove charge air hose	ENGINE 611, 612
2.3	Remove air filter housing	Model 203 with engine 272 with transmission 722.9 Model 203, 209 with engine 271 with transmission 722.6 Model 203, 209 with engine 646 with transmission 722.6 Model 203.076/276 with engine 113.988 with transmission 722.6 Model 209 with engine 272, 273 with transmission 722.9 Model 209.375/475 with engine 113 with transmission 722.6 Model 209.376/476 as of 4/24/04 with engine 113.987 with transmission 722.6 Model 209.376/476 as of 4/24/04 with engine 113.987 with transmission 722.9
		Model 203.076/276 with engine 113.988 Model 209.376/476 as of 4/24/04 with engine 113.987	AR09.10-P-1150AC
		Model 203.052/054/056/252/254/256/752/756, 209.354/356/454/456 with engine 272 with transmission 722.9 Model 209 with engine 273 with transmission 722.9	AR09.10-P-1150QB
		Model 203 (except 203.02/05/08/09/22/25/28/29), 209 with engine 271 with transmission 722.6	AR09.10-P-1150Q
		Model 203 (except 203.02/05/08/09/22/25/28/29), 209 with engine 646 with transmission 722.6	AR09.10-P-1150PM
3	Remove hot film mass air flow sensor	MODEL 203.076/ 276, MODEL 209.376/ 476
			AR07.07-P-1454SV
4	Detach filler pipe from engine
5.1	Detach lower engine compartment paneling	Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 111 with transmission 722.6 Model 203 (except 203.02/05/08/09/22/25/28/29), 209 with engine 112 with transmission 722.6 Model 203 (except 203.02/05/08/09/22/25/28/29), 209 with engine 113 with transmission 722.6 Model 203 (except 203.05), 209 with engine 272 with transmission 722.9 Model 209 with engine 273 with transmission 722.9
			AR61.20-P-1105P
5.2	Remove bottom sections of soundproofing	Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 611 with transmission 722.6 Model 203 (except 203.02/05/08/09/22/25/28/29), 209 with engine 612 with transmission 722.6 Model 203 (except 203.02/05/08/09/22/25/28/29), 209 with engine 646 with transmission 722.6
			AR94.30-P-5300P
6	Drain transmission oil at oil pan	If the transmission oil is burnt or contains wear debris, the oil cooling lines (49, 50) and the oil cooler must be rinsed.
		
		Flush oil line (49, 50) and oil cooler
		Transmission 722.9	AR27.55-P-0001PI
		Transmission 722.6	AR27.55-P-0001A
7.1	Remove rear exhaust system	Model 203 (except 203.08/28) with engine 112 with transmission 722.6 Model 203 with engine 111 with transmission 722.6 Model 203 with engine 271.921 with transmission 722.6 Model 203 with engine 271.940 with transmission 722.6 Model 203 with engine 271.946 with transmission 722.6 Model 203 with engine 271.948/957 with transmission 722.6 Model 203 with engine 611.962, 612.962 with transmission 722.6 Model 203 with engine 612.990 with transmission 722.6 Model 203, 209 with engine 646 with transmission 722.6 Model 209 with engine 112 with transmission 722.6 Model 209 with engine 113.968 with transmission 722.6 Model 209 with engine 271.940 with transmission 722.6 Model 209 with engine 271.955 with transmission 722.6 Model 209 with engine 612.967 with transmission 722.6 Model 209.376 up to 4/23/04, 209.476 with engine 113.987 with transmission 722.6 Model 209.376 up to 4/23/04, 209.476 with engine 113.987 with transmission 722.9
		MODEL 203 with ENGINE 611.962/ 612.962 MODEL 209 with ENGINE 612.967	AR49.10-P-7000PP
		MODEL 203, 209 with ENGINE 646	AR49.10-P-7000PM
		MODEL 203 with ENGINE 612.990	AR49.10-P-7000PF
		MODEL 203, 209 with ENGINE 112 MODEL 209 with ENGINE 113.968 MODEL 209.376 bis 23.4.04 with ENGINE 113.987 MODEL 209.476 with ENGINE 113.987	AR49.10-P-7000PV
		MODEL 203 with ENGINE 111	AR49.10-P-7000PR
		MODEL 203 with ENGINE 271.921/ 940/ 946/ 948/ 957 MODEL 209 with ENGINE 271.940/ 955	AR49.10-P-7000QK
7.2	Remove complete exhaust system	Model 203 with engine 113.988 with transmission 722.6 Model 203 with engine 272 with transmission 722.9 Model 203, 209 with engine 271.942 with transmission 722.6 Model 209 with engine 272, 273 with transmission 722.9 Model 209.376 as of 4/24/04 with engine 113.987 with transmission 722.6/9
		MODEL 203, 209 with ENGINE 271.942	AR49.10-P-7000QD
		MODEL 203 with ENGINE 113.988, MODEL 209.376 as of 24.4.2004 with ENGINE 113.987	AR49.10-P-7000AC
		MODEL 203 with ENGINE 272, MODEL 209 with ENGINE 272, 273	AR49.10-P-7000QB
8	Remove exhaust manifold with CAT	MODEL 203, 209 with ENGINE 271
		Model 203.040/240/740 with engine 271.948 with transmission 722.6 Model 203.042/242/742, 209.342/442 with engine 271.940 with transmission 722.6 Model 203.043/243/743, 209.343 with engine 271.942 with transmission 722.6 Model 203.046/246/746 with engine 271.946 with transmission 722.6 Model 203.730 with engine 271.921 with transmission 722.6 Model 203.741 with engine 271.957 with transmission 722.6 Model 209.341/441 with engine 271.955 with transmission 722.6	AR14.10-P-4095QK
9	Support transmission using telescopic lifter and transmission plate
	000 588 10 62 00 Support plate		WS26.00-P-3309B
	000 588 11 62 00 Major assembly mount		WS01.00-P-0092B
10	Remove rear engine cross member (12) with engine mount	Model 203 (except 203.02/05/08/09/22/25/28/29), 209 with transmission 722.6 Model 203.052/054/056/252/254/256/752/756, 209.354/356/372/376/454/456/472/476 with transmission 722.9
		Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 111 with transmission 722.6 Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 112 (except 112.916/953) with transmission 722.6 Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 113 with transmission 722.6 Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 271 with transmission 722.6 Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 646 with transmission 722.6 Model 209 with engine 112 with transmission 722.6 Model 209 with engine 113 with transmission 722.6 Model 209 with engine 271 with transmission 722.6 Model 209 with engine 646 with transmission 722.6 Model 209.376/476 with engine 113 with transmission 722.9	AR22.10-P-1160PR
		Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 611.962 with transmission 722.6 Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 612.962 with transmission 722.6 Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 612.990 with transmission 722.6 Model 209.316 with engine 612.967 with transmission 722.6	AR22.10-P-1160HC
		Model 203.052/252/752 with engine 272.920 with transmission 722.9 Model 203.054/254, 209.354/454 with engine 272.940 with transmission 722.9 Model 203.056/256/756, 209.356/456 with engine 272.960 with transmission 722.9 Model 209.372/472 with engine 273 with transmission 722.9	AR22.10-P-1160QB
		 Do not detach engine mount from rear engine cross member (12).
11	Disconnect front propeller shaft section (17) from transmission		AR41.10-P-0050-02EA
		 The flexible coupling remains on the front propeller shaft (17).
		When installing propeller shaft:
		
		Mount front propeller shaft to transmission
			AR41.10-P-0050-07EA
		 Self-locking nut, flexible coupling to transmission or front propeller shaft	*BA41.10-P-1001-01A
		 Torque wrench	*001589662100
12	Release pilot bushing from flexible coupling and push back front propeller shaft (17)		AR41.10-P-0050-09DA
		If pilot bushing is seized
		
		Prepare drift to release pilot bushing in flexible couplings.
		Drift for releasing the fitting sleeves in the flexible couplings	WF58.50-P-4110-01A
13	Detach shift rod (63) from below at intermediate lever
		Transmission 722.9 in model 203.052/054/056/252/254/256/752/756, 209.354/356/372/376/454/456/472/476	BT27.60-P-0021-01A
		 Observe lock washer variant.
14	Disconnect plug connector	Transmission 722.6 (except 722.649) in model 203 (except 203.02/05/08/09/22/25/28/29), 209	AR27.10-P-0500-01A
		TRANSMISSION 722.9	AR27.40-P-0700-01V
		 Bolt, heat shield to transmission housing	*BA27.40-P-1014-01A
		 Bolt, leaf spring to transmission housing	*BA27.40-P-1019-01A
15.1	Unclip cover and remove bolts (95)	TRANSMISSION 722.6/9 except TRANSMISSION 722.9 with angled threaded connection
		 Bolt, torque converter to driver spider	*BA27.20-P-1002-01C
15.2	Unclip cover from transmission bell housing and remove bolts (95)	Transmission 722.9 with angled threaded connection
			AR27.20-P-0100-01A
		 Bolt, torque converter to driver spider	*BA27.20-P-1002-01C
		 Socket wrench bit	*001589650900
		 Long wedge	*115589035900
16	Unscrew pipeline (21) from oil pan	 ENGINE 272, 273Screw/bolt, oil line bracket to oil pan	*BA01.45-P-1007-01M
		 ENGINE 111, 611, 612Bolt, oil pan to cylinder crankcase	*BA01.45-P-1001-01A
		 ENGINE 112, 113 (except 113.994)Bolt, oil pan to cylinder crankcase	*BA01.45-P-1001-01B
		 ENGINE 271Bolt, oil pan to cylinder crankcase	*BA01.45-P-1001-01H
		 ENGINE 646Bolt, oil pan to cylinder crankcase	*BA01.45-P-1001-01G
17.1	Detach oil cooling line (49) to oil cooler from transmission	ENGINE 111, 112, 113, 271, 272, 273
		 Before starting work, the area around the oil cooling lines (49) must be thoroughly cleaned in the area around the connecting points on the transmission. Even the smallest dirt particles in the hydraulic components can lead to malfunctions and a total failure of the transmission.
17.2	Detach oil cooling lines (50) to oil cooler	ENGINE 611, 612, 646
		 Before starting work, the area around the oil cooling lines (50) must be cleaned thoroughly at the connecting points on the transmission. Even the smallest dirt particles in the hydraulic components can lead to malfunctions and a total failure of the transmission.
18	Slacken bolt (50a)	ENGINE 611, 612, 646
19	Remove screw/bolts (2)	 TRANSMISSION 722.6Bolt, automatic transmission to engine	*BA27.40-P-1008-01A
		 TRANSMISSION 722.9Bolt, automatic transmission to engine	*BA27.40-P-1008-01A
20	Turn pipeline (21) downwards
21	Remove transmission downwards at an angle using telescopic lifter and transmission plate	 Secure torque converter to prevent it from falling out.
22	Take out torque converter with grab handles	If necessary
		TRANSMISSION 722.6	AR27.20-P-0500-01P
		TRANSMISSION 722.9	AR27.20-P-0500-01W
		TRANSMISSION 722.602/615/616/618/633/634/636/640/641/642/649/695/696/698/699Installation height of torque converter	*BE27.20-P-1001-01B
		TRANSMISSION 722.9Installed height of torque converter	*BE27.20-P-1001-01E
		Multi-purpose paste	*BR00.45-Z-1009-06A
		 Handles	*168589006200
		 Parallel rest	*126589043100
23	Remove corrosion from crankshaft		AR03.20-P-1000-01A
		Assembly cleaner	*BR00.45-Z-1028-04A
		Multi-purpose paste	*BR00.45-Z-1009-06A
	Check
24	Check threaded unions in driven plate spider or torque converter	 If the threaded unions are damaged or loose, the driven plate spider or the torque converter must be replaced.
25	Install in the reverse order
26	Perform basic programming	MODEL 203	AR00.19-P-0200P
		MODEL 209	AR00.19-P-0200Q
27	Check transmission oil level and correct if necessary	TRANSMISSION 722.6	AR27.00-P-0100AC
		TRANSMISSION 722.9	AR27.00-P-0270W
28	Read out fault memory and erase if necessary
			AD00.00-P-2000-04A
29	Perform transmission adaptation using diagnostic system	After replacement or repair of transmission
30	Reset data on service life of torque converter lockup clutch using diagnostic system	After replacing torque converter
 Warning	Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
31	Perform engine test run and check transmission for proper function and leak tightness

Check values for torque converter

Number	Designation			Transmission 722.600/601/602/603/604/605/608/611/614/615/616/619/626/629/634/637/638/640/642/660/661/695/699	Transmission 722.606/607/609/617/618/623/624/628/630/631/632/633/636/641/643/645/662/663/664/665/666/667/668/669/672/674/675/676/690/696/698
BE27.20-P-1001-01B	Installation height of torque converter	Distance from transmission housing	mm	7 (-2)	19,5 (-2)

Check values for torque converter

Number	Designation			Transmission 722.649
BE27.20-P-1001-01B	Installation height of torque converter	Distance from transmission housing	mm	20 (-2)

Test values for torque converter

Number	Designation				Transmission 722.9
BE27.20-P-1001-01E	Installed height of torque converter	Distance, bolt flange to transmission housing flange	Helical screwed connection	mm	9,5
			See picture		AR27.20-P-0500-01W
			Axial screwed connection	mm	19,5

 Oil pan

Number	Designation			Engine 111.951/955/958	Engine 111.92/94/952/956/957/96/97/98
BA01.45-P-1001-01A	Bolt, oil pan to cylinder crankcase	M6	Nm	8	10
		M8	Nm	20	25
		M10	Nm	–	–

 Oil pan

Number	Designation			Engine 611.960/961/962	ENGINE 612.961/962/963/965/966 ENGINE 613.961
BA01.45-P-1001-01A	Bolt, oil pan to cylinder crankcase	M6	Nm	9	9
		M8	Nm	20	20
		M10	Nm	–	–

 Oil pan

Number	Designation			Engine 612.967	Engine 612.990
BA01.45-P-1001-01A	Bolt, oil pan to cylinder crankcase	M6	Nm	9	9
		M8	Nm	20	20
		M10	Nm	–	–

 Oil pan

Number	Designation			Engine 112.910/ 911/912/913/914/ 915/917/920/921/ 922/923/940/941/ 942/943/944/945/ 946/947/949/951/ 954/955/960/961/ 970/972/973/976	Engine 113.940/ 941/942/943/944/ 960/961/962/963/ 965/967/968/969/ 980/981/982/984/ 986/992/995
BA01.45-P-1001-01B	Bolt, oil pan to cylinder crankcase	M6	Nm	9	9
		M8	Nm	20	20

 Oil pan

Number	Designation			Engine 113.987/988/991
BA01.45-P-1001-01B	Bolt, oil pan to cylinder crankcase	M6	Nm	9
		M8	Nm	20

 Oil pan

Number	Designation			Engine 646.951/961/962/963/966
BA01.45-P-1001-01G	Bolt, oil pan to cylinder crankcase	M6	Nm	9
		M8	Nm	20
		M10	Nm	–

 Oil pan

Number	Designation			Engine 271
BA01.45-P-1001-01H	Bolt, oil pan to cylinder crankcase	M630	Nm	9
		M690	Nm	9
		M835	Nm	20

 Oil pan

Number	Designation			Engine 272	Engine 273
BA01.45-P-1007-01M	Screw/bolt, oil line bracket to oil pan	M6	Nm	9	9

 Torque converter

Number	Designation				Transmission 722.6 (except 722.648)	Transmission 722.9
BA27.20-P-1002-01C	Bolt, torque converter to driver spider	Straight threaded connection	M8	Nm	42	42
		Angled threaded connection	Stage 1	Nm	4	4
			Stage 2	Nm	30	30
			Stage 3	°	90	90

 Housing

Number	Designation			Transmission 722.6 (except 722.660/661/662/663/666/673/674)	Transmission 722.9
BA27.40-P-1008-01A	Bolt, automatic transmission to engine	M1040	Nm	39	38
		M1045	Nm	–	38
		M1090	Nm	39	38
		M12	Nm	–	–

 Housing

Number	Designation		Transmission 722.6 (except 722.660/661/662/663/666/673/674)	Transmission 722.9
BA27.40-P-1014-01A	Bolt, heat shield to transmission housing	Nm	11	9

 Housing

Number	Designation		Transmission 722.6 (except 722.660/661/662/663/666/673/674)	Transmission 722.9
BA27.40-P-1019-01A	Bolt, leaf spring to transmission housing	Nm	8	5

 Propeller shaft

Number	Designation			Model 203	Model 209
BA41.10-P-1001-01A	Self-locking nut, flexible coupling to transmission or front propeller shaft	M10	Nm	40	40
		M12	Nm	60	60

001 589 66 21 00

Torque wrench

126 589 04 31 00

Parallel rest

168 589 00 62 00

Handles

001 589 65 09 00

Socket wrench bit

115 589 03 59 00

Long wedge

Repair materials

Number	Designation	Order number
BR00.45-Z-1009-06A	Multi-purpose paste	A 000 989 80 51
BR00.45-Z-1028-04A	Assembly cleaner	A 000 986 56 01

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