Remove/install torque converter clutch

AR25.40-W-0100A

Remove/install torque converter clutch

12.4.10

17.11.09

Clean any grease remains off the splines of the transmission input shaft and grease splines lightly when installing, added.

Step 8

*BR00.45-Z-1062-06A

 

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

 Danger!

Risk of injury caused by moving parts that can pinch, crush or, in extreme cases, even sever extremities

No parts of the body or limbs should be within the operating range of the mechanism when moving components.

AS00.00-Z-0009-01A

1

Remove torque converter clutch together with engine and transmission.

2

Drain oil at the oil drain screws (6) at the torque converter clutch housing and at the transmission

 Installation: Replace sealing rings on the oil drain screws (6).



*BA25.40-N-1017-01C



*BA26.40-N-1004-01D

3

Detach oil lines on retarder control valve

4

Remove engine from torque converter clutch (1).

5

Position transmission together with torque converter clutch (1) in a vertical position.

6

Install lifting device (3) on housing of torque converter clutch (1)



*625589025900

7

Remove torque converter clutch (1) from transmission

 Shim torque converter clutch (1) appropriately when putting down so that the studs are not damaged.

AR25.40-W-0100-01A



*BA25.40-N-1024-01C



*BA25.40-N-1025-01C



*625589025900

 Installation: Use new sealing ring (2) and coat flange face on transmission housing with sealant.

*BR00.45-Z-1015-01A

Tightening procedure for torque converter clutch

AR25.40-W-0100-02A



*BA25.40-N-1023-01C



*BA25.40-N-1024-01C



*BA25.40-N-1025-01C

8

Clean any grease remains off the spines of the transmission input shaft

 Installation: Grease splines of transmission input shaft lightly.

*BR00.45-Z-1062-06A

9

Install in the reverse order

10

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

11

Remove oil filler screw (4) and inspection plug (5)

12

Pour in Approx.. 25 l of oil at opening of oil filler screw (4)



Gear oils (Sheet 235.12)

Sheet 235.12

BB00.40-P-0235-12A

13

Start engine and allow to run with the highest gear engaged

 Engage parking brake.

14

Pour in oil at opening of oil filler screw (4) until oil runs out at inspection plug (5)

 Filling quantity depends on the version

Approx.. 25 to 40 l.

15

Screw in oil filler screw (4) and inspection plug (5)

 Install new sealing rings.



*BA25.40-N-1017-01C



*BA26.40-N-1011-01D

16

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.

17

Inspect transmission oil level, adjust to correct level if necessary

AR26.00-W-0100C

18

Check torque converter clutch (1) for leaks

 Visual inspection.

Number

Designation

Engine 541.9, 542.9
with code G02

BA25.40-N-1017-01C

Screw plug to torque converter clutch

M241.5

Nm

50

M261.5

Nm

65

BA25.40-N-1023-01C

Bolt of retarder housing on output side to retarder housing on drive side

M12115

Nm

100

M12110

Nm

45

M8

Nm

25

BA25.40-N-1024-01C

Nut, transmission to torque converter clutch

M12

Nm

90

BA25.40-N-1025-01C

Nut, transmission to torque converter clutch/master control unit

M12

Nm

45

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-1005-01D

Oil filler screw to transmission housing

Nm

60

BA26.40-N-1006-01D

Retaining panel of reverse shaft to transmission housing

Nm

60

BA26.40-N-1011-01D

Oil filler screw/oil check screw on transmission housing

Nm

60

Number

Designation

Order number

BR00.45-Z-1015-01A

Loctite 5203 sealant

A 002 989 71 20 10

BR00.45-Z-1062-06A

Lubricating grease, Olista Longtime, DB supply specification 6804.60

A 001 989 36 51 10