Remove/install transmission with torque converter

AR27.10-P-0500TS

Remove/install transmission with torque converter

06.03.2020

Transmission

722.9 in model 211.052/054/056/057/072/252/254/256/257/272

Modification notes

10.03.2014

"Remove corrosion from crankshaft" added.

Operation step 30

1

Oil cooling lines

6

Electrical connector

10

Flex disk

2

Rear engine mount

7

Cover

11

Screw

3

Shift rod

8

Screw

12

Rear engine cross member

4

Ground cable

9

Torque converter

13

Transmission

5

Shield

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 

Remove/install

1

Move selector lever into position "N"

2

Release parking brake

3

Switch off ignition and remove transmitter key

 Model 211.052/054/056/057/072/252/254/256/257/272 with transmission 722.9
with code 889 (KEYLESS-GO)
Press the KEYLESS-GO start and stop button repeatedly until the ignition is switched off.
Remove the KEYLESS GO transmitter card or transmitter key from the vehicle and store beyond the reach of the transmitter (min. 2 m).

4

Open engine hood

AR88.40-P-1000T

5

Detach ground line from battery

Model 211.052/054/056/057/072 with transmission 722.9

AR54.10-P-0003T

Topical note

Notes on battery

AH54.10-P-0001-01A

Model 211.252/254/256/257/272 with transmission 722.9

AR54.10-P-0003TA

6

Raise vehicle with vehicle lift

AR00.60-P-1000T

7

Remove bottom engine compartment paneling

AR61.20-P-1105T

8

Detach electrical connector of heated O2 probes

9

Unclip all electrical feed lines from retaining clamps at transmission (13)

10

Remove shield (5) and disconnect electrical connector (6)

 Bolt, heat shield to transmission housing

*BA27.40-P-1014-01A

11

Detach left and right catalytic converter from exhaust manifold

AR49.10-P-7000TS

12

Remove cover (7) from the transmission bell

13

Remove bolts (11) from the torque converter (9)

TRANSMISSION 722.9 With angled threaded connection of torque converter

AR27.20-P-0100-01A

 Turn engine by the crankshaft center bolt in the direction of rotation of the engine until the bolts (11) are accessible through the cutout in the transmission bell.

 Bolt, torque converter to driver spider

*BA27.20-P-1002-01C

 Socket wrench bit

*001589650900

 Long wedge

*115589035900

14

Press torque converter (9) evenly off driven plate using long wedge

 Do not damage the torque converter (9) and driven plate.

 Long wedge

*115589035900

15

Detach ground line (4) from transmission (13)

 Bolt, ground line to transmission housing

*BA27.40-P-1013-01A

16

Detach oil cooling lines (1) from transmission (13)

AR27.10-P-0502-01TS


Before starting work, the area around the oil cooling lines (1) must be thoroughly cleaned at the separation points on the transmission (13).
Even the smallest dirt particles in the hydraulic components can lead to malfunctions and a total failure of the transmission (13).

 Seal the connections at the transmission (13) and oil cooling lines (1).

 Installation: Install new seals.

 Bolt, oil line to transmission housing

*BA27.55-P-1002-01D

 Screw, oil cooler oil line to oil pan

*BA27.55-P-1003-01D

 Bolt, clamp to oil line

*BA27.55-P-1004-01D

 Screw, oil cooler oil line clamp to oil pan

*BA27.55-P-1006-01D

Assembly cleaner

*BR00.45-Z-1028-04A

 Record plug

*129589009100

17

Detach retaining clamps of oil cooling lines (1) from engine oil pan and place oil cooling lines (1) to one side

AR27.10-P-0502-01TS

 Do not bend or kink the oil cooling lines (1).

Assembly cleaner

*BR00.45-Z-1028-04A

 Bolt, oil line to transmission housing

*BA27.55-P-1002-01D

 Screw, oil cooler oil line to oil pan

*BA27.55-P-1003-01D

 Bolt, clamp to oil line

*BA27.55-P-1004-01D

 Screw, oil cooler oil line clamp to oil pan

*BA27.55-P-1006-01D

 Record plug

*129589009100

18

Detach starter from transmission (13)

Model 211 with engine 272 (except 272.944/972) with transmission 722.9

AR15.30-P-7100TS

Model 211 with engine 273 (except 273.962) with transmission 722.9

AR15.30-P-7100TX

 Place starter to the side with lines connected and secure to prevent it falling down.

19

Detach shift rod (3) from the range selector lever of the transmission (13)

 Installation: Replace the retaining clip.

20

Support transmission (13) with transmission jack and plate

21

Remove rear engine crossmember (12) together with rear engine mount (2)

AR22.10-P-1180TS

 Installation:
Screw in the bolts securing the rear engine crossmember (12) to the frame floor assembly by hand.
This will prevent the threaded holes from being damaged.

 Check the rear engine mount (2) for wear.

22

Attach a colored marking indicating position of propeller shaft relative to transmission output flange

 This is to ensure reinstallation at the ex-factory installation position, otherwise drive line vibrations can be produced.

23

Detach front propeller shaft from transmission output flange

AR41.10-P-0050-02T

 Apply colored identification of propeller shaft position relative to transmission output flange in order when installing to reproduce installation position created at plant as otherwise drive line vibrations can occur.

 The flexible coupling (10) remains on the propeller shaft.

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

*BA41.10-P-1001-01A

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

*BA41.10-P-1001-01A

When installing front propeller shaft at transmission:



Mount front propeller shaft to transmission

AR41.10-P-0050-07I

24

Loosen fitting sleeves of front flexible coupling (10) from transmission output flange

AR41.10-P-0050-09DA

25

Support engine at engine oil pan


The engine must not tilt against the splash wall when the transmission (13) is removed.
The brake lines installed there will otherwise be damaged.

26

Lower transmission jack slightly and secure transmission (13) on the transmission platform using the tensioning strap

27

Remove screws/bolts (8)

 Bolt, automatic transmission to engine

*BA27.40-P-1008-01A

28

Remove transmission (13) downward at an angle

 Secure torque converter (9) to prevent it from falling out.

 Installation: Align the through bores of the torque converter (9) with the threaded unions in the driven plate.

29

Remove torque converter (9)

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

30

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

31

Check threaded unions in the driven plate

If threaded unions are damaged or loose:



The driven plate must be replaced.

32

Check flex disk (10)



AP41.10-P-4152Z

If damage is detected during the visual inspection:



Replace flexible coupling (10) subject to a separate repair order.

33

Install in the reverse order

34

Check transmission oil level and correct if necessary

AR27.00-P-0270W

35

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



AD00.00-P-2000-04A

36

Perform transmission adaptation using diagnostic system

After replacement or repair of transmission (13)

37

Reset data on service life of torque converter lockup clutch using diagnostic system

After replacement of torque converter (9)

 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

38

Perform engine test run and check transmission (13) for proper operation 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

 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

–

 Housing

Number

Designation

Transmission 722.9

BA27.40-P-1013-01A

Bolt, ground line to transmission housing

Nm

9

 Housing

Number

Designation

Transmission 722.9

BA27.40-P-1014-01A

Bolt, heat shield to transmission housing

Nm

9

 Transmission oil cooling

Number

Designation

Transmission 722.9

BA27.55-P-1002-01D

Bolt, oil line to transmission housing

Banjo bolt

Stage 1

Nm

5

Stage 2

°

90

Hexalobular bolt

Nm

12

 Transmission oil cooling

Number

Designation

Transmission 722.9

BA27.55-P-1003-01D

Screw, oil cooler oil line to oil pan

Nm

12

 Transmission oil cooling

Number

Designation

Transmission 722.9

BA27.55-P-1004-01D

Bolt, clamp to oil line

Nm

8

 Transmission oil cooling

Number

Designation

Transmission 722.9

BA27.55-P-1006-01D

Screw, oil cooler oil line clamp to oil pan

Nm

8

 Propeller shaft

Number

Designation

Model 211

BA41.10-P-1001-01A

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

M10

Nm

40

M12

Nm

60

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