Remove/install CVT electric controller unit

AR27.19-P-0201AK

Remove/install CVT electric controller unit

14.12.09

16.7.07

Note on replacing bolts, added

Step 17



Removing

 Danger!

Risk of injury to skin or eyes caused by hydraulic fluid spraying out under high pressure. Risk of poisoning caused by swallowing hydraulic fluid

Depressurize the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses.

AS00.00-Z-0013-01A



Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



Absolute cleanliness is essential when working on the transmission. Before opening the hydraulic system, thoroughly clean the area surrounding the separation point. Only lint-free cleaning cloths may be used. Even the smallest dirt particles in the hydraulic components can lead to malfunctions and a total failure of the transmission.

For repairs always wear oil-resistant, fiber-free gloves which are lined with rubber.

The transmission components should be stored in clean surroundings. Here we recommend covering the components or storing them in a clean plastic box with cover



Before removing the electric controller unit read out fault memory with STAR DIAGNOSIS and prepare printouts of the initial brief test report, the fault surroundings data report of all fault entries and the analysis sheet. Fill in analysis sheet and submit the documents to the Quality Engineering Center (QEC)



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

1

Move selector lever to position "P"

 Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

2

Raise vehicle with vehicle lift

AR00.60-P-1000AK

3

Remove oil pan (3)

AR27.10-P-7030AK

4

Release fuse on electrical connector (2); to do so slide fuse slider (2s) in direction of travel, until the position shown here is reached

5

Press down lock (2v) and disconnect electrical connector (2) from CVT electric controller unit (Y3/9)

6

Remove bolts (4)

7

Remove bolts (5)

8

Take appropriate measures to prevent CVT electric controller unit (Y3/9) from falling down

9

Remove bolts (5a)

10

Remove CVT (continuously variable automatic transmission) electric controller unit (Y3/9) from transmission housing (1)

11

Check sealing rings (6) for damage; fit new sealing rings if necessary



Install

12

Insert CVT (continuously variable automatic transmission) electric controller unit (Y3/9) into transmission housing (1)

AR27.19-P-0200-01AK

13

Loosely position bolts (5a)

14

Loosely position bolts (4)

15

Loosely position bolts (5)

16

Tighten bolts (5, 5a)

 Bolt, electrohydraulic controller unit to transmission housing

*BA27.19-P-1001-03A

17

Tighten bolts (4)

 Use new bolts.

 Bolt, electric controller unit to oil pump

*BA27.19-P-1002-03A

18

Plug and lock electrical connector (2) onto CVT (continuously variable automatic transmission) electric controller unit (Y3/9)

19

Install oil pan (3)

AR27.10-P-7030AK

20

Fill transmission with transmission fluid

AR27.00-P-0270AK

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

21

Check transmission oil level

 In order to avoid damage to the transmission, it is absolutely essential to follow the work procedure and the Specifications for Operating Fluids.

AR27.00-P-0100AK

22

Read out fault memory



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

23

Check transmission for leaks and function

Number

Designation

Trans-missions
722.800/
801

BA27.19-P-1001-03A

Bolt, electrohydraulic controller unit to transmission housing

Stage 1

Nm

4

Stage 2

°

90

BA27.19-P-1002-03A

Bolt, electric controller unit to oil pump

with spacer washer

Nm

6

without spacer washer

Stage 1

Nm

4

Stage 2

°

180