Detach/attach transmission housing on torque converter housing.

AR27.50-D-0601A

03.12.2013

TRANSMISSION	722.681 in MODEL 902.6, 903.6, 904.6, 905.6
TRANSMISSION	722.683 in MODEL 906.1/2/6/7
TRANSMISSION	722.684 in MODEL 906.1/2/6/7
TRANSMISSION	722.685 in MODEL 906.1/2/6/7
TRANSMISSION	722.686 in MODEL 906.1/2/6/7

Detach/attach transmission housing on torque converter housing.

D27.50-1104-09

1	Screw	5	Shim	9	Radial shaft sealing ring
2	Torque converter housing	6	Grooved ball bearing	10	Output flange
3	Screw	7	Retaining ring	11	Collar nut
4	Transmission housing	8	Thrust plate	12	Teflon rings

	Remove
1	Remove automatic transmission	TRANSMISSION 722.681	AR27.10-D-0502A
		TRANSMISSION 722.683 TRANSMISSION 722.684 TRANSMISSION 722.685 TRANSMISSION 722.686 in MODEL 906.1/2/6/7	AR27.10-D-0502B
2	Remove torque converter	TRANSMISSION 722.681 in MODEL 902.6, 903.6, 904.6, 905.6
			AR27.20-D-0500-01B
		 Handle	*126589016200
3	Fasten transmission on assembly stand		AR27.10-D-0600-01A
		 Assembly stand	*116589065900
		 Mounting plate	*140589346300
4	Remove electrohydraulic controller unit		AR27.19-D-0210A
5	Remove output flange (10)	TRANSMISSION 722.681 TRANSMISSION 722.683/684/685/686 without CODE ZG1 (Engageable all-wheel drive) without CODE ZG2 (Permanent all-wheel drive) without CODE ZG3 (Engageable all-wheel drive with gear reduction) without CODE ZG4 (Permanent all-wheel drive with gear reduction)	AR27.50-D-0620-02A
		TRANSMISSION 722.683/684/685/686 with CODE ZG1 (Engageable all-wheel drive) with CODE ZG2 (Permanent all-wheel drive) with CODE ZG3 (Engageable all-wheel drive with gear reduction) with CODE ZG4 (Permanent all-wheel drive with gear reduction)	AR27.50-D-0620-02B
		 Socket wrench bit	*126589020900
		 Pin wrench	*901589000700
		 Puller	*000589893300
		 Socket wrench bit	*126589020900
		 Puller	*000589893300
6	Remove radial shaft sealing ring (9)
7	Remove thrust plate (8) and circlip (7)
8	Remove grooved ball bearing (6) from output shaft, check it and replace, if necessary		AR27.50-D-0604-01A
		 Puller	*001589503300
		 Collet chuck	*140589063400
9	Remove shim (5)
10	Remove screws/bolts (1, 3)	 The threaded holes must not be recut with the conventional thread taps. Otherwise the thread gets destroyed. Only blow out threaded holes using compressed air.
11	Detach transmission housing (4) from torque converter housing (2)	 If necessary, detach transmission housing (4) by applying light impacts to it using a plastic mallet.
	Install
12	Check installation position of Teflon rings (12)	 Both Teflon rings (12) must be in the grooves of the output shaft.
13	Mount transmission housing (4) on converter housing (2)	 The lamella toothings of the multidisk brakes B2 and B3 must be aligned with each other. Turn the output shaft to and fro when mounting transmission housing (4).
14	Tighten bolts (1, 3).	 Replace bolts (1, 3).
		 Screw/bolt, transmission housing to converter housing	*BA27.40-N-1006-01B
15	Install grooved ball bearing (6)	 Only when new parts, e.g. gear sets or output shaft have been installed.
		 The plastic cage must face with the closed side towards the park pawl gear .
		 Drift	*711589011500
16	Measure axial play between park pawl gear and grooved ball bearing (6) and determine the thickness of shim (5)		AR27.50-D-0600-06A
		 Only when new parts, e.g. gear sets or output shaft have been installed.
		End play between park pawl gear and grooved ball bearing	*BE27.50-N-1001-01B
		 Parallel rest	*126589043100
17	Remove grooved ball bearing (6)		AR27.50-D-0604-01A
		 Only when new parts, e.g. gear sets or output shaft have been installed.
		 Puller	*001589503300
		 Collet chuck	*140589063400
18	Install shim (5)	 If new parts, z.g. gear sets or output shaft were installed, use shim (5) with determined thickness.
19	Install grooved ball bearing (6)	 The plastic cage must face with the closed side towards the park pawl gear .
		 Drift	*711589011500
20	Adjust axial play of grooved ball bearing (6) on the output shaft		AR27.50-D-0604-02A
		Axial play between grooved ball bearing and retaining ring	*BE27.50-N-1002-01B
21	Install thrust plate (8)
22	Press radial shaft sealing ring (9) into transmission housing (4)	 Fit a new radial shaft sealing ring (9).
		 Drift	*140589121500
23	Install output flange (10)	TRANSMISSION 722.681 TRANSMISSION 722.683/684/685/686 without CODE ZG1 (Engageable all-wheel drive) without CODE ZG2 (Permanent all-wheel drive) without CODE ZG3 (Engageable all-wheel drive with gear reduction) without CODE ZG4 (Permanent all-wheel drive with gear reduction)	AR27.50-D-0620-02A
		TRANSMISSION 722.683/684/685/686 with CODE ZG1 (Engageable all-wheel drive) with CODE ZG2 (Permanent all-wheel drive) with CODE ZG3 (Engageable all-wheel drive with gear reduction) with CODE ZG4 (Permanent all-wheel drive with gear reduction)	AR27.50-D-0620-02B
		 Collar nut, output flange to output shaft	*BA27.50-N-1001-01A
		 Collar nut, output flange to output shaft	*BA27.50-N-1001-01A
		 Socket wrench bit	*126589020900
		 Pin wrench	*901589000700
		 Drift	*716589011500
		 Socket wrench bit	*126589020900
		 Drift	*716589011500
24	Install electrohydraulic controller unit		AR27.19-D-0210A
25	Insert torque converter	TRANSMISSION 722.681 in MODEL 902.6, 903.6, 904.6, 905.6
			AR27.20-D-0500-01B
		The difference in height "A" between the contact surface of the converter angled brackets and the transmission flange	*BE27.20-N-1001-01C
		 Handle	*126589016200
26	Install automatic transmission	TRANSMISSION 722.681 in MODEL 902.6, 903.6, 904.6, 905.6	AR27.10-D-0502A
		TRANSMISSION 722.683 in MODEL 906.1/2/6/7 TRANSMISSION 722.684 in MODEL 906.1/2/6/7 TRANSMISSION 722.685 in MODEL 906.1/2/6/7 TRANSMISSION 722.686 in MODEL 906.1/2/6/7	AR27.10-D-0502B

Torque converter

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