Disassemble, assemble and seal

AR28.10-S-1004EA

Disassemble, assemble and seal

18.02.2020

Model

447 with transmission 722.9

with code ZG2 (Permanent all-wheel drive)

3

Radial shaft sealing ring

4

Intermediate housing

5

Automatic transmission

8

Bolts

9

Cover

10

Retaining ring

11

Output shaft

13

Connecting bolt

14

Ring gear

15

Needle bearing

23

Drain screw

24

Transfer case

4

Intermediate housing

5

Automatic transmission

14

Ring gear

16

Planet carrier

17

Bolts

19

Differential side gear (front axle differential propeller shaft)

20

Radial shaft sealing ring

5

Automatic transmission

20

Radial shaft sealing ring

 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

Topical note

Notes on using electrical or pneumatic screwdrivers/impact wrenches

AH00.00-N-0017-01A

Topical note

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

AH00.00-P-0020-01A

Topical note

General information on repair work on transmission

AH27.00-S-1000-01PS

Notes on automatic transmission

AH27.19-P-0001-01NKB



Remove

1

Move DIRECT SELECT lever to "N" position.

2

Raise vehicle.

AR00.60-S-1000E

3

Drain transmission oil from automatic transmission (5).



Automatic transmission fluid and oil filter change

AP27.00-S-2702E

 Do not yet remove oil pan, collect transmission oil.

 Commercially available devices/tools
Collection bowl



Check

4

Check collected transmission oil for metal shavings.

If metal shavings are present



Replace automatic transmission (5).

Remove/install transmission with torque converter

AR27.10-S-0500E

5

Remove oil pan of automatic transmission (5).

AR27.10-S-7030E



Install

6

Install oil pan of automatic transmission (5).

AR27.10-S-7030E

 Use new overflow pipe.



Remove

7

Remove propeller shaft with flex disk.

AR41.10-S-0050-14E

8

Remove engine crossmember at rear.

Model 447 with engine 651 with transmission 722.9
with code ZG2 (Permanent all-wheel drive)

AR22.10-S-1170EA

 Do not remove support tools.

9

Remove intelligent service module.

AR27.19-S-0550E

10

Lower automatic transmission (5) slightly.

11

Remove front axle differential propeller shaft from differential side gear (19).

Model 447 with engine 651 with transmission 722.9
with code ZG2 (Permanent all-wheel drive)

AR41.10-S-0070EA



Disassemble

12

Drain transmission oil from transfer case (24).

 Commercially available devices/tools
Collection bowl

13

Screw in drain screw (23).

 Replace seal.

 Drain screw to intermediate housing

*BA28.10-N-1001-01EA

14

Remove output flange.

AR27.50-S-0620-02E

 Collar nut, output flange to output shaft

*BA27.50-N-1001-01C

 Socket wrench bit

*126589020900

 Pin wrench

*901589000700

 Puller

*000589893300

15

Remove radial shaft sealing ring (3).

If leakage is present.

AR27.40-S-0205E

16

Remove cap (9).

 To do so, remove screws (8).

17

Remove retaining ring (10).

 Check retaining ring (10) for deformation and damage.

If deformation or damage is present.



Replace retaining ring (10).

18

Remove output shaft (11).

19

Move automatic transmission (5) to "P" position.

 Assembly tool

*722589030900

20

Remove needle bearings (15).

 Check needle bearings (15) for wear and damage.

If wear or damage is present.



Replace needle bearings (15).

21

Remove connecting bolt (13).

 Dispose of connecting bolt (13).

22

Remove ring gear (14).

 WIS Service Media
wsm://03_201408_01

If ring gear (14) is firmly seated.



Detach ring gear (14).

AR28.10-S-1001-02EA

 Extraction tool

*722589013300

23

Remove planet carrier (16).

24

Remove intermediate housing (4).

 To do this, remove screws (17).

25

Remove differential side gear (19).

26

Remove radial shaft sealing ring (20) using suitable tool.


When removing the radial shaft sealing ring (20) always place a rag on the automatic transmission (5), as shown, to support the tool.
Otherwise, the sealing surface on the automatic transmission (5) will be damaged and it will leak.



Assemble

27

Install a new radial shaft sealing ring (20).

 Ensure correct installation position.

 Drift

*722589141500

28

Install differential side gear (19).


The  assembly sleeve must be used.
Otherwise, the radial shaft sealing ring (20) may be damaged.

 Check that the  assembly sleeve is correctly seated.

 Assembly sleeve

*722589061400

29

Remove assembly sleeve.

 Assembly sleeve

*722589061400



Clean

30

Clean sealing surfaces on automatic transmission (5) and intermediate housing (4).

AR01.00-P-0050-01A

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

31

Install intermediate housing (4).

 To do so, screw in screws (17).

 Bolt, intermediate housing to transmission housing

*BA28.10-N-1004-01EA

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

32

Install planet carrier (16).

33

Install ring gear (14).

 To do so, press on ring gear (14) by hand and screw in new connecting bolt (13).

 Bolt, annulus gear to output shaft

*BA28.10-N-1005-01EA

34

Install needle bearings (15).

35

Move automatic transmission (5) to "N" position.

 Assembly tool

*722589030900

36

Install output shaft (11).

37

Install retaining ring (10).

 Check retaining ring (10) is correctly seated.

If the retaining ring (10) is not correctly seated.



Correct seating of retaining ring (10).



Clean

38

Clean sealing surfaces on cap (9) and intermediate housing (4).

AR01.00-P-0050-01A

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

39

Install cap (9).

 Bolt, cover to intermediate housing

*BA28.10-N-1003-01EA

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

40

Install new radial shaft sealing ring (3).

If leakage was present,

AR27.40-S-0205E

41

Install output flange.

AR27.50-S-0620-02E

 Collar nut, output flange to output shaft

*BA27.50-N-1001-01C

 Socket wrench bit

*126589020900

 Pin wrench

*901589000700

 Puller

*000589893300

 Drift

*716589011500

42

Prefill transfer case (24) with 0.7 l transmission oil.



Automatic transmission fluids (ATF) (specification 236.15)

BB00.40-P-0236-15A

 Replace filling screw.

 Filling screw to intermediate housing

*BA28.10-N-1002-01EA



Install

43

Mount front axle differential propeller shaft.

Model 447 with engine 651 with transmission 722.9
with code ZG2 (Permanent all-wheel drive)

AR41.10-S-0070EA

44

Install intelligent service module.

AR27.19-S-0550E

45

Install engine crossmember at rear.

Model 447 with engine 651 with transmission 722.9
with code ZG2 (Permanent all-wheel drive)

AR22.10-S-1170EA

46

Mount propeller shaft with flex disk.

AR41.10-S-0050-14E

 Bolt, propeller shaft center support bearing to underfloor

*BA41.10-N-1003-01H

 Bolt, flexible coupling to transmission

*BA41.10-N-1004-01H

47

Fill automatic transmission (5) with transmission oil.

AR27.00-S-0270E



Check

 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

48

Check for leak tightness and proper operation with engine running.

 Gear assembly

Number

Designation

Transmission 722.9

BA27.50-N-1001-01C

Collar nut, output flange to output shaft

Nm

200

 Complete transfer case

Number

Designation

Model 447 with transmission 722.9 with code ZG2

BA28.10-N-1001-01EA

Drain screw to intermediate housing

Nm

30

 Complete transfer case

Number

Designation

Model 447 with transmission 722.9 with code ZG2

BA28.10-N-1002-01EA

Filling screw to intermediate housing

Nm

20

 Complete transfer case

Number

Designation

Model 447 with transmission 722.9 with code ZG2

BA28.10-N-1003-01EA

Bolt, cover to intermediate housing

Nm

8

 Complete transfer case

Number

Designation

Model 447 with transmission 722.9 with code ZG2

BA28.10-N-1004-01EA

Bolt, intermediate housing to transmission housing

Nm

20

 Complete transfer case

Number

Designation

Model 447 with transmission 722.9 with code ZG2

BA28.10-N-1005-01EA

Bolt, annulus gear to output shaft

Stage 1

Nm

30

Stage 2

°

180

 Propeller shaft

Number

Designation

Model 447, 448

BA41.10-N-1003-01H

Bolt, propeller shaft center support bearing to underfloor

Nm

58

 Propeller shaft

Number

Designation

Model 447, 448

BA41.10-N-1004-01H

Bolt, flexible coupling to transmission

Stage 1

Nm

60

Stage 2

°

60

Repair materials

Number

Designation

Order number

BR00.45-Z-1013-01A

Sealant, Loctite 5970, 50 ml

A 003 989 98 20 10

BR00.45-Z-1038-04A

Loctite 7200

Henkel AG & Co. KGaA
http://www.loctite.de

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09