Remove/install transmission with torque converter

AR27.10-P-0500PI

Remove/install transmission with torque converter

06.03.2020

Transmission

722.9 in model 203, 209 with engine 642

Modification notes

07.03.2014

"Remove corrosion from crankshaft" added.

Operation step 22

1

Oil cooling line

4

Heat shield

7

Bolts

2

Oil cooling line

5

Electrical connector

9

Bolts

3

Screw

6

Bolts

10

Bolts

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 

Remove/install

1

Remove engine cover

AR01.10-P-2405PI

2

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

3

Remove right air filter housing

AR09.10-P-1150PI

4

Remove bottom sections of soundproofing

AR94.30-P-5300P

5

Remove catalytic converter

AR49.10-P-5500PI

6.1

Remove diesel particulate filter

Model 203, 209 with engine 642 with transmission 722.9
with code 474 (Diesel particulate filter)

AR14.40-P-1000PI

6.2

Remove center exhaust pipe

Model 203, 209 with engine 642 with transmission 722.9
except code 474 (Diesel particulate filter)

AR49.10-P-7000PI

7

Drain transmission oil at oil pan

 Installation: Replace seal.

 Drain screw to oil pan

*BA27.10-P-1001-03D

If the transmission oil is burnt or contains wear particles, the oil cooling lines (1, 2) and the oil cooler must be flushed out:



Flush oil line and oil cooler

AR27.55-P-0001PI

8

Unscrew bracket for oil cooling lines (1, 2) at right and left from oil pan

 Bracket to oil pan top section

*BA01.45-P-1004-01Q

9

Disconnect oil cooling lines (1, 2) from transmission


Before starting work, the area around the oil cooling lines (1, 2) 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.

 Record plug

*129589009100

10

Remove bolt (3)

11

Pull heat shield (4) out of guide and remove

12

Disconnect electric plug connection (5) from transmission

13

Support transmission using transmission plate and telescopic lifter



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

14

Remove rear engine cross member with engine mount

 To do so, remove screws/bolts (6, 7).

 Do not detach engine mount from rear engine cross member.

 MODEL 203Bolt/nut, rear engine crossmember to body

*BA22.10-P-1003-01D

 MODEL 203Bolt or nut, rear engine mount to transmission

*BA22.10-P-1006-01D

 MODEL 209Bolt, rear engine support to frame floor assembly

*BA22.10-P-1005-03B

 MODEL 209Bolt/nut, rear engine mount to bracket or transmission

*BA22.10-P-1003-03B

15

Detach front propeller shaft from transmission

AR41.10-P-0050-02PI

When mounting:



Mount front propeller shaft to transmission

AR41.10-P-0050-07PI

 Grease quantity

*BF41.10-P-1001-01A

 Self-locking nut, flexible coupling to transmission or front propeller shaft

*BA41.10-P-1001-01A

16

Detach flexible coupling to front propeller shaft

 To be able to remove the flexible coupling to the front propeller shaft, the transmission must be lowered far enough that the flexible coupling is accessible.

17

Unclip shift rod from transmission


Secure the shift rod to the side of the propeller shaft tunnel.
This avoids damage.

18

Remove screw/bolts (10)

AR27.20-P-0100-01A

 To do this remove the cover on the transmission bell.

 Bolt, torque converter to driver spider

*BA27.20-P-1002-01C

 Long wedge

*115589035900

 Socket wrench bit

*001589650900

19

Remove bolts for transmission to oil pan and crankcase

 Bolt, automatic transmission to engine

*BA27.40-P-1008-01A

20

Remove transmission downwards at an angle using telescopic lifter and transmission plate

 Secure torque converter to prevent it from falling out.

21

Remove torque converter

If necessary

AR27.20-P-0500-01W

Installed height of torque converter

*BE27.20-P-1001-01E

Multi-purpose paste

*BR00.45-Z-1009-06A

 Handles

*168589006200

 Parallel rest

*126589043100

22

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

23

Check threaded unions in driver spider

 If the threaded unions are damaged and loose, the driven plate spider must be replaced.

24

Install in the reverse order

25

Fill transmission, check transmission oil level and correct if necessary

AR27.00-P-0270W

26

Perform basic programming

MODEL 203

AR00.19-P-0200P

MODEL 209

AR00.19-P-0200Q

27

Read out fault memory using the diagnostic system and clear if necessary



AD00.00-P-2000-04A

28

Perform transmission adaptation using diagnostic system

After replacement or repair of transmission

29

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

30

Perform engine test run and check transmission for proper function and leak tightness

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 642

BA01.45-P-1004-01Q

Bracket to oil pan top section

M6

Nm

14

M8

Nm

20

 Engine suspension, engine mounts, engine supports

Number

Designation

Engine 642 in model 203

BA22.10-P-1003-01D

Bolt/nut, rear engine crossmember to body

Nm

40

 Engine mount, engine support (engine side)

Number

Designation

Model 209

BA22.10-P-1003-03B

Bolt/nut, rear engine mount to bracket or transmission

Nm

50

 Engine mount, engine support (engine side)

Number

Designation

Model 209

BA22.10-P-1005-03B

Bolt, rear engine support to frame floor assembly

Nm

50

 Engine suspension, engine mounts, engine supports

Number

Designation

Engine 642 in model 203

BA22.10-P-1006-01D

Bolt or nut, rear engine mount to transmission

Nm

40

 Automatic transmission oil pan

Number

Designation

Transmission 722.9

BA27.10-P-1001-03D

Drain screw to oil pan

Nm

22

 Torque converter

Number

Designation

Transmission 722.9

BA27.20-P-1002-01C

Bolt, torque converter to driver spider

Straight threaded connection

M8

Nm

42

Angled threaded connection

Stage 1

Nm

4

Stage 2

Nm

30

Stage 3

°

90

 Housing

Number

Designation

Transmission 722.9

BA27.40-P-1008-01A

Bolt, automatic transmission to engine

M1040

Nm

38

M1045

Nm

38

M1090

Nm

38

M12

Nm

–

 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

 Propeller shaft

Number

Designation

Model 203

Model 209

BF41.10-P-1001-01A

Grease quantity

Centering sleeve of propeller shaft

g

6

6

Sheet

BB00.40-P-0267-00A

BB00.40-P-0267-00A

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