Remove/install transmission with torque converter

AR27.10-S-0500A

Remove/install transmission with torque converter

7.12.09

 

Remove/install

1

Disconnect battery ground line

AR54.10-S-0005A

2

Drain transmission oil



AP27.00-D-2701A

 Danger!

Risk of injury to skin and eyes due to scalding with hot coolant which sprays out. Risk of poisoning due to swallowing coolant

Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.

Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

3

Drain coolant



AP20.00-D-2080A

4

Remove coolant hose (3) from coolant pipe (1).

5

Unscrew bolts (2) and (4) and press coolant pipe (1) away to one side



*BA01.45-N-1001-01A

6

Remove cover (6) on oil pan

7

Unscrew screws (7)

 Crank the engine at the crankshaft until the bolts (7) are accessible.
Continue turning the engine respectively by approx. 120° in direction of engine rotation.

AR01.00-S-0120A



*BA27.20-N-1003-01C

8

Remove bolts (5)



*BA27.10-N-1001-04A

9

Remove axle/engine subframe with engine

Engine 111.948/978

AR31.35-S-4200A

Engine 111.950/980

AR31.35-S-4200C

10

Remove intermediate shaft

AR33.30-S-7706M

11

Detach drive shaft on left of output flange

AR33.30-S-6500M

12

Raise transmission and engine using a suitable lifting device (14) on assembly bracket until the transmission bearing (9) is relieved of load

13

Unscrew mating bearing (15) of shift cable



*BA27.10-N-1008-04A

14

Undo bolt (8)



*BA27.10-N-1009-04A

15

Detach bracket (10) from axle/engine subframe



*BA27.10-N-1010-04A

16

Support engine between the support fixture for the axle/engine subframe and oil pan using a suitable pad (11) underneath

 Pad (11) approx. 15 cm high.

17

Lower transmission and engine until the engine contacts the pad (11) underneath

18

Separate cable tie on bracket (13)

 Installation: Replace cable ties.

19

Unscrew bolts (12) on circumference of transmission and remove bracket (13)

 Installation: The transmission must abut the engine correctly, do not draw together with bolts.



*BA27.10-N-1001-04A

20

Separate transmission from engine with lifting device and put down securely

 Ensure that the torque converter remains in the oil pump guide, if necessary. 

Insert torque converter.

AR27.20-S-0500-01A

 Installation: Screw studs (17) M830 mm into the thread on the torque converter (installation aid). When inserting the transmission the stud (17) must engage in the bore suitable for this on the drive plate. After installing the engine with axle/engine subframe, unscrew the stud (17) through the opening in the oil pan again.

21

Modify detachable parts of transmission

 Only when replacing the transmission.

AR27.10-S-0500-02A



*BA27.10-N-1011-04A



*BA27.55-N-1001-01A



*BA27.55-N-1001-01E

22

Install in the reverse order

23

Check adjustment of shift cable and adjust if necessary

Model 638 up to VIN 400544

AR27.60-S-1470A

Model 638 as of VIN 400545

AR27.60-S-1470B

Number

Designation

Engine
111.948/
978

Engine
111.950/
980

BA01.45-N-1001-01A

Bolt, oil pan to cylinder crankcase

M6

Nm

10

10

M8

Nm

23

23

Number

Designation

Model 638 with engine 111.948/978, 601.970

Model 638 with engines 111.950
/980, 611.980

BA27.10-N-1001-04A

Automatic transmission to engine

M10

Nm

55

55

BA27.10-N-1008-04A

Counterholder (shift cable) to transmission housing

Nm

15

15

BA27.10-N-1009-04A

Transmission bearing to axle/engine subframe

Nm

50

-

BA27.10-N-1010-04A

Bracket to axle/engine subframe

Nm

27

-

BA27.10-N-1011-04A

Shift lever to shift shaft

Nm

15

15

Number

Designation

Model 638 with Series 111, 601.970, 611.980 engine

BA27.20-N-1003-01C

Torque converter to driver

Nm

42

Number

Designation

Model
638.014/034/094/114/134/194/
214/234/294
with engine
111.948/950/978/
980
with code G40

BA27.55-N-1001-01A

Oil lines to transmission housing

Nm

25

Number

Designation

Model
638.074/094/174/194/274/294
with code G40

BA27.55-N-1001-01E

Oil lines to transmission housing

Nm

25