Remove/install automatic transmission

AR27.10-D-0502W

Remove/install automatic transmission

18.07.2019

Transmission

722.9 in model 906

Modification notes

31.08.2018

Work procedure revised, method adapted, picture representation added, special tools added

Operation steps 1 to 49

31.08.2018

Socket wrench socket 001 589 65 09 00 inserted

Operation step 1

AR27.00-D-0200-01B

31.08.2018

Work procedure revised

Operation steps 1 to 6

AR27.00-D-0200-01B

31.08.2018

Work procedure revised, special tools added

Operation steps 1 to 12

AR27.20-D-0100-01W

Shown on model 906 without code XM0 (Facelift) with code JD1 (Tachograph with digital technology)

1

Rear engine support

2

Engine mount

3

Automatic transmission

4

Support plate

5

Tensioning strap

6

Motor

7

Wooden block

B6/12

Rpm sensor (with code J19 (Tachograph 1 day/2 driver automatic (EU)) or code JD1 (Tachograph with digital technology) or code JD2 (EU digital tachograph with rotational speed + additional recorder))

8

Bracket

9

Bolts

10

Diesel particulate filter

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 Caution

Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil

Wear protective gloves, protective clothing and safety glasses.
Do not pour transmission oil into beverage bottles.

AS00.40-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on automatic transmission

AH27.19-P-0001-01NKB



Remove

1

Connect vehicle diagnosis system and transfer data from electrohydraulic controller unit to vehicle diagnosis system.

If electrohydraulic controller unit or automatic transmission (3) is replaced.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-D-2000-04SD

2

Move selector lever to "P" position.

3

Detach ground line of on-board electrical system battery.

AR54.10-D-0003SD

4

Raise vehicle.

AR00.60-D-1000H

5

Remove filler pipe upper part.

Transmission 722.9 in model 906Transmission with guide tube for oil dipstick

AR27.10-D-0500-04W

6

Remove filler pipe lower part.

If automatic transmission (3) is replaced or if repair work is carried out on the automatic transmission (3).

Transmission 722.9 in model 906Transmission with guide tube for oil dipstick

AR27.10-D-0500-04W

7

Remove auxiliary oil pump.

If automatic transmission (3) is replaced or if repair work is carried out on the automatic transmission (3).

Transmission 722.9 in model 906
with code MJ7 (ECO start/stop function)
Transmission 722.9 in model 906
with code MJ8 (ECO start/stop function)

AR27.30-D-0651WE

8

Drain transmission oil from torque converter and oil pan.

If automatic transmission (3) is replaced or if repair work is carried out on the automatic transmission (3).

AR27.00-D-0200-01B


After loosening the overflow pipe at the oil pan, it is imperative to remove the oil pan and to install the overflow pipe again at the oil pan.
Otherwise the transmission may be damaged.

 Commercially available devices/tools
Collecting pan

 Drain screw on oil pan

*BA27.10-N-1005-04B

 Drain screw to torque converter

*BA27.20-N-1001-01F

 Transmission 722.9 in model 906 with engine 642
Socket wrench bit

*001589650900

 Transmission 722.9 in model 906 with engine 651
except code H08 (Roof-mounted air conditioning system, reinforced)
Counterholder

*651589084000

 Transmission 722.9 in model 906 with engine 651
with code H08 (Roof-mounted air conditioning system, reinforced)
Counterholder

*651589004000

 Drift

*722589031500

 Ratchet box wrench

*906589000300

9

Remove holder (8) of diesel particulate filter (10).

 To do this, remove bolts (9) .

10

Remove oil lines at automatic transmission (3).

AR27.10-D-0502-01W

 Seal connections. Collect escaping transmission oil.

 Commercially available devices/tools
Collecting pan

 Record plug

*129589009100

11

Disconnect electrical connector at auxiliary oil pump and expose electrical wiring harness.

If the auxiliary oil pump is installed.

Transmission 722.9 in model 906
with code MJ7 (ECO start/stop function)
Transmission 722.9 in model 906
with code MJ8 (ECO start/stop function)

AR27.30-D-0651WE

12

Disconnect electrical connector at automatic transmission (3) and expose electrical wiring harness.

AR27.19-D-0750-01WE

13

Remove torque converter from drive plate.

AR27.20-D-0100-01W

 Turn crankshaft in direction of engine rotation until screws of torque converter are accessible through opening in transmission housing.

 Transmission 722.9 in model 906 with engine 642
Socket wrench bit

*001589650900

 Transmission 722.9 in model 906 with engine 651
with code H08 (Roof-mounted air conditioning system, reinforced)
Counterholder

*651589004000

 Transmission 722.9 in model 906 with engine 651
except code H08 (Roof-mounted air conditioning system, reinforced)
Counterholder

*651589084000

14

Remove propeller shaft.

AR41.10-D-0050H

15

Remove speed sensor (B6/12) at automatic transmission (3) and expose electric line.

Transmission 722.9 in model 906.1/2/6/7
with code J19 (Tachograph 1 day/2 drivers automatic (CM))
Transmission 722.9 in model 906.1/2/6/7
with code JD1 (Digital tachograph)
Transmission 722.9 in model 906.1/2/6/7
with code JD2 (Tachograph digital EC with rpm + aux-recorder)

AR54.61-D-5500-01A

16

Unhook selector lever shift cable from automatic transmission (3).

AR27.60-D-0100-02WE

17

Lift automatic transmission (3) using major assembly mount and mounting plate (4) until rear engine mount (2) is relieved of load.



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

 Place suitable wooden block between automatic transmission (3) and mounting plate (4).

18

Support engine (6) at integral carrier above front axle spring using a suitable wooden block (7) and lower automatic transmission (3).

19

Remove rear engine carrier (1) together with engine mount (2).

Transmission 722.9 in model 906 with engine 642

AR22.10-D-1170SD

Transmission 722.9 in model 906 with engine 651

AR22.10-D-1170WE

20

Remove screws of automatic transmission (3).

 Do not yet remove a screw on upper side of automatic transmission (3). The screw must remain in the transmission housing for securing. The bolts have different shank lengths. Mark their installation locations.

 Transmission 722.9 in model 906 with engine 642
Remove cover of starter opening here. The starter remains in the crankcase.

21

Support automatic transmission (3) with major assembly support and mounting plate (4) and secure with tensioning strap (5).



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

 Commercially available devices/tools
Tensioning strap

22

Remove automatic transmission (3).


During removal of automatic transmission (3), secure torque converter using a suitable tool to prevent it from falling out.
Otherwise the torque converter may be damaged.

 To do so, remove last screw on upper side of automatic transmission (3).

23

Remove torque converter.

If automatic transmission (3) is replaced or if repair work is carried out on the automatic transmission (3).

Transmission 722.9 in model 906 with engine 642
Transmission 722.9 in model 906 with engine 651

AR27.20-D-0500-01TS

 Commercially available devices/tools
Collecting pan



Check

24

Check radial shaft sealing ring of oil pump.

If the torque converter was removed.

If a leak or damage is present,



replace radial shaft sealing ring of oil pump.

AR27.40-D-0300WE

25

Check threaded inserts in drive plate for damage and loose seat.

If corresponding findings are present,



Replace drive plate.

Transmission 722.9 in model 906 with engine 642

AR03.30-S-8003SE

Transmission 722.9 in model 906 with engine 651

AR03.30-D-8003WE



Install

26

Insert torque converter.

If the torque converter was removed.

Transmission 722.9 in model 906 with engine 642
Transmission 722.9 in model 906 with engine 651

AR27.20-D-0500-01TS


Insert torque converter without tilting it and do not apply force.
Otherwise, the axial end stop of the torque converter will be destroyed.


Always check for correct seating of the torque converter.
An incorrectly inserted torque converter will become damaged when the automatic transmission (3) is installed, and causes damage to the oil pump.

 Commercially available devices/tools
Vernier caliper, digital

Transmission 722.9 in model 906 with engine 642
Transmission 722.9 in model 906 with engine 651Torque converter protrusion to transmission housing

*BE27.20-N-1001-01TS

Multi-purpose paste

*BR00.45-Z-1009-06A

 Parallel rest

*126589043100

27

Install automatic transmission (3) and secure with a screw at the top side of transmission.

 Bolt, transmission housing to engine

*BA27.10-N-1003-04B

28

Remove tensioning strap (5) and slightly lower major assembly mount with mounting plate (4).



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

 Commercially available devices/tools
Tensioning strap

29

Attach automatic transmission (3) to engine (6).

 Note different shank lengths of bolts. Do not yet screw in screws (9) of holder (8).

 Bolt, transmission housing to engine

*BA27.10-N-1003-04B

30

Attach torque converter to drive plate.

AR27.20-D-0100-01W

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

 Turn crankshaft in direction of engine rotation until respective screws of torque converter are accessible through opening in transmission housing.

 Bolt, torque converter to drive plate or drive star

*BA27.20-N-1002-01F

 Long wedge

*115589035900

 Transmission 722.9 in model 906 with engine 642
Socket wrench bit

*001589650900

 Transmission 722.9 in model 906 with engine 651
with code H08 (Roof-mounted air conditioning system, reinforced)
Counterholder

*651589004000

 Transmission 722.9 in model 906 with engine 651
except code H08 (Roof-mounted air conditioning system, reinforced)
Counterholder

*651589084000

31

Install auxiliary oil pump.

If the auxiliary oil pump was removed.

Transmission 722.9 in model 906
with code MJ7 (ECO start/stop function)
Transmission 722.9 in model 906
with code MJ8 (ECO start/stop function)

AR27.30-D-0651WE

 Do not yet connect the electrical connector of the auxiliary oil pump.

32

Install filler pipe lower part.

If automatic transmission (3) was replaced or if repair work was carried out on automatic transmission (3).

Transmission 722.9 in model 906Transmission with guide tube for oil dipstick

AR27.10-D-0500-04W

 Bolt, filler pipe to transmission housing

*BA27.10-N-1002-04B

33

Install filler pipe upper part.

Transmission 722.9 in model 906Transmission with guide tube for oil dipstick

AR27.10-D-0500-04W

 Bolt, filler pipe to bracket

*BA27.10-N-1013-04B

 Bolt, filler pipe to cylinder head

*BA27.10-N-1001-04B

34

Hook selector lever shift cable into automatic transmission (3).

AR27.60-D-0100-02WE

Long-life grease

*BR00.45-Z-1001-06A

35

Attach oil lines at automatic transmission (3).

AR27.10-D-0502-01W

 Bolt, oil line to transmission housing

*BA27.55-N-1002-01I

 Bolt, dual clamp to oil line

*BA27.55-N-1004-01I

 Record plug

*129589009100

36

Install holder (8) of diesel particulate filter (10).

 To do so, screw in screws (9).

 Transmission 722.9 in model 906 with engine 642Bolt, diesel particulate filter to transmission bracket

*BA14.40-N-1017-01B

 Transmission 722.9 in model 906 with engine 651Nut/bolt, bracket to front exhaust system

*BA49.10-N-1003-01I

 Bolt, bracket to transmission

*BA27.10-N-1011-04B

 Bolt, transmission housing to engine

*BA27.10-N-1003-04B

37

Connect electrical connector to auxiliary oil pump and secure electrical wiring harness.

Transmission 722.9 in model 906
with code MJ7 (ECO start/stop function)
Transmission 722.9 in model 906
with code MJ8 (ECO start/stop function)

AR27.30-D-0651WE

 Observe installation position of electrical wiring harness.

38

Connect electrical connector to automatic transmission (3) and secure electrical wiring harness at filler pipe.

AR27.19-D-0750-01WE

 Observe installation position of electrical wiring harness.

 Bolt, heat shield to transmission housing

*BA27.40-N-1007-01I

39

Attach speed sensor (B6/12) at automatic transmission (3) and secure electric line at automatic transmission (3).

Transmission 722.9 in model 906.1/2/6/7
with code J19 (Tachograph 1 day/2 drivers automatic (CM))
Transmission 722.9 in model 906.1/2/6/7
with code JD1 (Digital tachograph)
Transmission 722.9 in model 906.1/2/6/7
with code JD2 (Tachograph digital EC with rpm + aux-recorder)

AR54.61-D-5500-01A

 Replace lead seal.

 Transmission 722.9 in model 906.1/2/6/7 with engine 642
with code J19 (Tachograph 1 day/2 drivers automatic (CM))
Transmission 722.9 in model 906.1/2/6/7 with engine 642
with code JD1 (Digital tachograph)
Transmission 722.9 in model 906.1/2/6/7 with engine 642
with code JD2 (Tachograph digital EC with rpm + aux-recorder)
Transmission 722.9 in model 906.1/2/6/7 with engine 651
with code J19 (Tachograph 1 day/2 drivers automatic (CM))
Transmission 722.9 in model 906.1/2/6/7 with engine 651
with code JD1 (Digital tachograph)
Transmission 722.9 in model 906.1/2/6/7 with engine 651
with code JD2 (Tachograph digital EC with rpm + aux-recorder)Bolt, vehicle speed sensor to transmission housing

*BA54.00-N-1003-01A

40

Install propeller shaft.

AR41.10-D-0050H

41

Slightly lift automatic transmission (3) with major assembly mount and mounting plate (4).



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

42

Install rear engine carrier (1) together with engine mount (2).

Transmission 722.9 in model 906 with engine 642

AR22.10-D-1170SD

Transmission 722.9 in model 906 with engine 651

AR22.10-D-1170WE

43

Remove wooden block (7) for supporting engine (6) and lower automatic transmission (3).

44

Remove oil pan of automatic transmission (3), attach oil suction pipe and reinstall oil pan.

If transmission oil was drained from oil pan.

AR27.10-D-7030WE

45

Lower vehicle.

46

Attach ground line of on-board electrical system battery.

AR54.10-D-0003SD

47

Transfer stored data from vehicle diagnosis system into new electrohydraulic controller unit.

If automatic transmission (3) or electrohydraulic controller unit was replaced.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-D-2000-04SD

48

Check and correct oil level in automatic transmission(3).

Transmission 722.9 in model 906Transmission with guide tube for oil dipstick

AR27.00-D-0101WE

Transmission 722.9 in model 906Transmission without guide tube for oil dipstick

AR27.00-D-0270WE

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

49

Carry out engine test run and check leak tightness of automatic transmission (3).

 Visual inspection only.

Check values for torque converter

Number

Designation

Transmission 722.9 in model 906, 907 with engine 642

Transmission 722.9 in model 906, 907 with engine 651

BE27.20-N-1001-01TS

Torque converter protrusion to transmission housing

Torque converter bolted 4 times

mm

14,6

24,8

 Diesel particulate filter

Number

Designation

Engine 642.896 in model 906

Engine 642.898 in model 906

BA14.40-N-1017-01B

Bolt, diesel particulate filter to transmission bracket

Nm

23

23

 Diesel particulate filter

Number

Designation

Engine 642.993 in model 906

BA14.40-N-1017-01B

Bolt, diesel particulate filter to transmission bracket

Nm

-

 Complete automatic transmission

Number

Designation

Transmission 722.9

BA27.10-N-1001-04B

Bolt, filler pipe to cylinder head

Nm

8

 Complete automatic transmission

Number

Designation

Transmission 722.9

BA27.10-N-1002-04B

Bolt, filler pipe to transmission housing

Nm

8

 Complete automatic transmission

Number

Designation

Transmission 722.9

BA27.10-N-1003-04B

Bolt, transmission housing to engine

Nm

38

 Complete automatic transmission

Number

Designation

Transmission 722.9

BA27.10-N-1005-04B

Drain screw on oil pan

Nm

22

 Complete automatic transmission

Number

Designation

Transmission 722.9

BA27.10-N-1011-04B

Bolt, bracket to transmission

Nm

23

 Complete automatic transmission

Number

Designation

Transmission 722.9

BA27.10-N-1013-04B

Bolt, filler pipe to bracket

Nm

8

 Torque converter

Number

Designation

Transmission 722.9

BA27.20-N-1001-01F

Drain screw to torque converter

M8

Nm

10

M10

Nm

15

 Torque converter

Number

Designation

Transmission 722.9

BA27.20-N-1002-01F

Bolt, torque converter to drive plate or drive star

Straight threaded connection

M8

Nm

42

Angled threaded connection

Stage 1

Nm

4

Stage 2

Nm

30

Stage 3

°

90

 Housing

Number

Designation

Transmission 722.9

BA27.40-N-1007-01I

Bolt, heat shield to transmission housing

Nm

9

 Transmission oil cooling

Number

Designation

Transmission 722.9

BA27.55-N-1002-01I

Bolt, oil line to transmission housing

Banjo bolt

Stage 1

Nm

5

Stage 2

°

90

Hexalobular bolt

Nm

12

 Transmission oil cooling

Number

Designation

Transmission 722.9

BA27.55-N-1004-01I

Bolt, dual clamp to oil line

Nm

8

 Exhaust system

Number

Designation

Engine 651 in model 906
except code MS3 (Engine version EURO 3)

BA49.10-N-1003-01I

Nut/bolt, bracket to front exhaust system

Nm

23

 Pulse generator

Number

Designation

Model 906 with engine 642

Model 906 with engine 651

BA54.00-N-1003-01A

Bolt, vehicle speed sensor to transmission housing

Nm

10

10

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11

BR00.45-Z-1009-06A

Multi-purpose paste

A 000 989 80 51