Flush out automatic transmission and torque converter

AR27.55-P-0100A

Flush out automatic transmission and torque converter

15.8.11

 

Remove/install

 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

 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

 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



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



Before opening the hydraulic system, thoroughly clean the area surrounding the separation point. Even the smallest dirt particles, introduced into the hydraulic components, can lead to malfunctions and a total failure of the hydraulic system

1.1

Remove the rear section of the engine compartment paneling

Vehicles with gasoline engine except model 461 and 463

Model 129, 202, 208, 210

AR61.20-P-1105AB

Model 140

Model 163 except 163.113/128/136/154/157

AR61.20-P-1105GH

Model 163.113/128/136/154/157

Model 170

AR61.20-P-1105A

Model 171

AR61.20-P-1105V

Model 199

AR61.20-P-1105SLR

Model 209, 203 with gasoline engine

AR61.20-P-1105P

Model 211

AR61.20-P-1105T

Model 219

AR61.20-P-1105TX

Model 215, 220

AR61.20-P-1105M

Model 230

AR61.20-P-1105R

Model 240

AR61.20-P-1105H

1.2

Remove rear part of bottom sections of soundproofing

Vehicles with diesel engine except model 461 and 463

Model 140

Model 163

AR94.30-P-5400GH

Type 202.1

AR94.30-P-5300A

Model 209, 203 with diesel engine

AR94.30-P-5300P

Model 210

AR94.30-P-5300AB

Model 211

AR94.30-P-5300T

Model 220

AR94.30-P-5300M

2

Remove drain plug from the transmission oil pan and drain transmission oil

 The transmission oil should have an operating temperature of 80 °C.



*BA27.10-P-1001-03A

3

Detach transmission oil pan and install a new transmission oil filter

 Caution: when removing the transmission oil pan, approx. 2.5 liters of transmission oil will still be in the transmission oil pan.

4

Mount transmission oil pan

 Install new gasket.



*BA27.10-P-1002-03A

5

Detach clamps for right oil cooling line (2) from engine oil pan

 Model 163, 171, 211, 219, 220, 461, 463

*BA27.55-P-1008-01B

 Model 199, 203, 209, 215, 230

*BA27.55-P-1003-01B

6

Remove banjo bolt (3) from connection (1) on right oil cooling line (2)

 Model 163, 171, 211, 219, 220, 461, 463

*BA27.55-P-1002-01B

 Model 199, 203, 209, 215, 230

*BA27.55-P-1002-01B

7

Join connection fitting (4) with an approx. 1.5 meter long hose using a hose clamp (5)

 Remove the connection fitting (4) from the  hand pump.



*210589007100

8

Mount banjo bolt (3) and oil cooling line (2) to connection fitting (4)

9

Hold hose into a bucket with a scale on it

 The bucket should have a capacity of 10 liters.

10

Unlock cap (93)

 Break off plate (93a) using a suitable tool and press out locking pin (93b) remaining in cap (93) downwards.

11

Detach cap (93) from oil filler pipe

12

 Mount funnel onto oil filler pipe and fill transmission with 5 liters of oil

 The entire flushing procedure requires 14 liters of transmission oil.



*126589126300

Flushing



An assistant is required for the flushing procedure

13

Start the engine and drain transmission oil via the hose into the bucket

 Always observe work procedure and Specifications for Operating Fluids, otherwise transmission will be damaged.

14

Once 3 liters of transmission oil are in the bucket stop the engine immediately

15

Pour in 3 liters of transmission oil

16

Repeat flushing procedure twice

17

Check oil level in automatic transmission, correct if necessary

AR27.00-P-0100AC

18

Install in the reverse order

19

Carry out engine test run, checking the transmission for function and oil leaks

Number

Designation

Trans-mission 722.6 except 722.628/
648/649

Trans-mission 722.628

Trans-mission 722.648

Trans-mission 722.649

BA27.10-P-1001-03A

Oil drain screw to oil pan

Nm

20

20

20

22

BA27.10-P-1002-03A

Bolt, oil pan to transmission housing

Nm

8

8

8

8

Number

Designation

Trans-mission 722.6 in model 163

Trans-mission 722.6 in model 199

Trans-mission 722.6 in model 170, 171, 203, 209, 210, 215, 219, 220, 230, 240

BA27.55-P-1002-01B

Banjo bolt or union nut, oil cooler line to torque converter and transmission housing

Stage 1

Nm

20

20

5

Stage 2

°

-

-

90

Hexalobular bolt

Nm

-

-

-

BA27.55-P-1003-01B

Bolt, oil cooler line to engine oil pan

Nm

11

-

11

BA27.55-P-1008-01B

Bolt, oil cooler line retaining clamp to oil pan

Nm

8

-

8

Number

Designation

Trans-mission 722.6 in model 204, 216, 221

Trans-mission 722.6 in model 211

Trans-mission 722.6 in model 461, 463

BA27.55-P-1002-01B

Banjo bolt or union nut, oil cooler line to torque converter and transmission housing

Stage 1

Nm

5

5

20

Stage 2

°

90

90

-

Hexalobular bolt

Nm

12

-

-

BA27.55-P-1003-01B

Bolt, oil cooler line to engine oil pan

Nm

11

11

-

BA27.55-P-1008-01B

Bolt, oil cooler line retaining clamp to oil pan

Nm

-

8

8