Remove/install automatic transmission

AR27.10-D-0502A

Remove/install automatic transmission

15.2.12

 

Remove/install

1

Move selector lever to position "P"

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

2

Disconnect battery ground line

 Isolate ground lead to prevent accidental contact.



Notes on battery

AH54.10-P-0001-01A

3

Remove oil drain screw of oil pan (6) and drain automatic transmission fluid into a clean container

 If the transmission oil is burnt or contains particles, the oil cooler lines and oil cooler must be flushed out: 

Flush out oil cooler lines and oil cooler.

AR27.55-D-0001A

 Installation: Install new sealing ring (5).



*BA27.10-N-1005-04B

4

Remove end cap (8) from the underside of the converter housing

5

Using a suitable socket wrench bit on the crankshaft pulley, crank engine until the torque converter oil drain screw (7) is at the bottom

6

Remove torque converter oil drain screw (7) and drain the automatic transmission fluid into a clean container



*BA27.40-N-1007-01B

7

Remove oil filler pipe

AR27.10-D-0500-04A



*BA27.10-N-1003-04B



*BA27.10-N-1001-04B



*BA27.10-N-1002-04B

8

Remove retaining bracket (4)

 Installation: The retaining bracket (4) is asymmetric. The angular side must be on the left in the direction of travel.



*BA41.10-N-1004-01B

9

Take off propeller shaft (1) at transmission

 Tie propshaft (1) up on the right-hand side.

 Installation: Replace bolts (2).



*BA41.10-N-1001-01B



Notes on installing propeller shaft

AH41.10-N-0001-01A

10

Remove lines at automatic transmission

AR27.10-D-0502-01A



*BA01.45-N-1001-01H



*BA27.10-N-1004-04B

11

Detach shift cable at transmission

 Installation: Ensure that the transmission selector lever is in position "N".

AR27.60-D-0100-01A

12

Unscrew converter housing from driver

AR27.20-D-0100-01B



*BA27.20-N-1002-01A



*BA46.20-N-1003-01C

13

Support engine

 Insert wooden block between oil pan and front axle beam.

14

Remove bolts, starter to transmission housing, engine flange (B)



*BA15.30-N-1001-01G

15

Remove bolts of transmission housing to engine flange (A) on the underside of transmission

 One bolt of the transmission housing to engine flange (A) must remain on the top side of the transmission for locking in the transmission housing.



*BA27.10-N-1003-04B

15

Place hydraulic transmission jack under transmission and raise slightly

 Secure the transmission on the hydraulic transmission lever using a tensioning strap.

16

Remove rear engine crossmember (12)

 First unscrew the nuts of the engine crossmember (13) on rear engine crossmember (12). Then unscrew the transmission bearing bolts (9).

 Installation: Pay attention to the correct position of the rubber mount (11). The cast-on rubber pin on the rubber mount (11) must be led through the bore of the upper bearing shell for transmission suspension (10).



*BA22.10-N-1004-01L



*BA22.10-N-1007-01L

17

Remove the last transmission housing bolt on the engine flange (A) on the top side of the transmission

 Installation: Check the position of the torque converter and drive plate again. For this purpose, align the bores in the torque converter and drive plate above one another using a suitable drift.



*BA27.10-N-1003-04B

18

Draw out transmission towards the rear and lower

 When moving out the transmission ensure that the torque converter remains in the transmission housing.

 Installation: Align torque converter and driving plate relative to one another. Grease the torque converter journal with Molykote.

Ensure dowel bolts are installed in correct position at housing flange.

AR27.10-D-0502-03A

19

Secure the torque converter to prevent it falling out

 The torque converter must be engaged fully in the oil pump splines.

 Installation: As a check, check the installed dimension of the torque converter.

*BE27.20-N-1001-01C

20

Install in the reverse order

21

Inspect ATF level of automatic transmission

 Shift selector in position "P"

AR27.00-D-0101A

22

Conduct a road test

Number

Designation

Transmission
722.681

BE27.20-N-1001-01C

The difference in height "A" between the contact surface of the converter angled brackets and the transmission flange

mm

55

Number

Designation

Engine 612.981

Engine 647.981

BA01.45-N-1001-01H

Bolt, oil pan to cylinder crankcase

M6

Nm

9

9

M8

Nm

20

20

M10

Nm

-

-

Number

Designation

Engine 612.965/
966/981/
990

Engine
647.981

BA15.30-N-1001-01G

Bolt connecting starter to crankcase

Nm

40

42

Number

Designation

Engine 612.981

Engine 647.981

BA22.10-N-1004-01L

Nut/bolt, rear engine crossmember to console

Nm

45

45

BA22.10-N-1007-01L

Rear engine mount to engine cross member

Nm

45

45

Number

Designation

Trans-mission
722.681

BA27.10-N-1001-04B

Bolt, oil filler pipe to cylinder head

Nm

8

BA27.10-N-1002-04B

Bolt, oil filler pipe to transmission housing

Nm

8

BA27.10-N-1003-04B

Bolt connecting transmission housing to engine

Nm

38

BA27.10-N-1004-04B

Bolt, oil line to transmission housing

Nm

34

BA27.10-N-1005-04B

Oil drain screw to oil pan

Nm

20

Number

Designation

Transmission 722.681

BA27.20-N-1002-01A

Bolt, torque converter to drive plate

Nm

50

Number

Designation

Trans-mission
722.681

BA27.40-N-1007-01B

Oil drain screw to torque converter

M81

Nm

-

M101

Nm

14

Number

Designation

Model
690.6, 901, 902, 903, 904, 905 except Minibus Sprinter Low Floor

BA41.10-N-1001-01B

Propeller shaft on transmission

M101

Stage 1

Nm

70

Stage 2

°

-

Screw headE14

Stage 1

Nm

-

Stage 2

°

-

M121.5

Screw headE14

Stage 1

Nm

-

Stage 2

°

-

Screw headE18

Stage 1

Nm

-

Stage 2

°

-

BA41.10-N-1004-01B

Bolt, retaining bracket to frame floor

M121.5

Nm

100

Number

Designation

Model
WD1/WD2/ WD3/
WD6/ WD7/
XD1/ XD2/XD3/
XD4/XD5/ XD6/
XD7/
YD1/YD2/ YD3/
YD4/ YD5/YD6/
YD7

BA41.10-N-1001-01B

Propeller shaft on transmission

M101

Stage 1

Nm

70

Stage 2

°

-

Screw head E14

Stage 1

Nm

-

Stage 2

°

-

M121.5

Screw head E14

Stage 1

Nm

-

Stage 2

°

-

Screw head E18

Stage 1

Nm

-

Stage 2

°

-

BA41.10-N-1004-01B

Bolt, retaining bracket to frame floor

M121.5

Nm

100

Number

Designation

Model
690, 901, 902, 903, 904, 905

Model
WD1/WD2/
WD3/WD6/
WD7/XD1/
XD2/XD3/
XD4/XD5/
XD6/XD7/
YD1/YD2/
YD3/YD4/
YD5/YD6/
YD7

BA46.20-N-1003-01C

Bolt, steering to front axle

Stage 1

Nm

25

25

Stage 2

Nm

45

45

Stage 3

°

90

90