D27.10-1136-09
Shown on transmission 722.685 without all-wheel drive |
1 | Transmission | 3 | Exhaust bracket | 5 | Torsion bar bracket | ||
2 | Transmission crossmember | 4 | Catalytic converter |
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. | |
| Notes on self-locking nuts and bolts | ||
| Remove | ||
1 | Shift selector lever into position P | ||
2 | Disconnect battery ground line | ||
3 | Unscrew filler pipe from cylinder head | ||
4 | Raise vehicle | ||
5 | Secure vehicle on vehicle lift | ||
6 | Drain transmission oil out of torque converter and transmission (1), and screw drain screws back in again | ||
Drain screw on oil pan | |||
Oil drain bolt to torque converter | |||
Ratchet box wrench | |||
Drain plate | |||
7 | Remove lines from transmission (1) | ||
8 | Disconnect electrical connector on transmission (1) | ||
Check pilot bushing for leaks and seal if necessary: | |||
| |||
Remove/install pilot bushing of electrohydraulic controller unit | |||
9 | Remove left and right torsion bar holder (5) | ||
10 | Unbolt torque converter from drive plate | Turn engine at crankshaft until the bolts are accessible through the bore (arrow) in the crossmember. | |
11 | Remove propeller shaft to rear axle | ||
On vehicles with three-piece propeller shaft only the front propeller shaft must be removed. | |||
12 | Remove propeller shaft to front axle from transfer case, and attach at side on floor assembly |
| |
13 | Remove transfer case |
| |
14 | Detach rpm sensor from transmission (1) |
| |
15 | Unhook Bowden cable selector lever from transmission (1) | ||
16 | Raise transmission (1) slightly with telescopic lifter | ||
| 000 588 11 62 00 Major assembly mount | ||
17 | Using a suitable piece of wood, support the engine at the crossmember above the front axle spring and lower transmission (1) | ||
18 | Mark installation position of transmission crossmember (2) | The mounting holes are arranged asymmetrically. | |
19 | Remove transmission crossmember (2) together with rear engine mount | ||
20 | Remove exhaust bracket (3) | On engine 272, both exhaust brackets (3) must be removed. | |
21 | Remove filler pipe | ||
22 | Disconnect electrical connectors of left oxygen sensor | Transmission 722.685 in model 906.1/2/6/7 with engine 272 | |
23 | Remove left catalytic converter (4) together with the oxygen sensor | Transmission 722.685 in model 906.1/2/6/7 with engine 272 | |
24 | Unbolt transmission (1) from engine | One bolt on the top side of the transmission must still remain in the transmission housing for security. | |
25 | Support transmission (1) with telescopic lifter and transmission plate, and secure with a strap | ||
| 000 588 10 62 00 Support plate | ||
| 000 588 11 62 00 Major assembly mount | ||
26 | Unscrew bolt on top side of the transmission and remove transmission (1) | When moving out the transmission (1), make sure that the torque converter remains in the transmission housing. | |
27 | Remove torque converter | ||
| Install | ||
28 | Insert torque converter | ||
Long-life grease | |||
29 | Insert transmission (1) and secure with a bolt on the top side of the transmission | ||
30 | Remove strap, telescopic lifter and transmission plate | ||
| 000 588 10 62 00 Support plate | ||
| 000 588 11 62 00 Major assembly mount | ||
31 | Bolt transmission (1) onto engine | Do not yet tighten bolts with which additional brackets are attached. | |
Bolt, transmission housing to engine | |||
32 | Thread in filler pipe and attach to transmission housing | ||
Bolt, filler pipe to transmission housing | |||
Bolt, transmission housing to engine | |||
33 | Insert selector lever Bowden cable onto transmission (1) and apply light coating of grease | ||
Long-life grease | |||
34 | Tighten torque converter on drive plate | Turn engine at crankshaft until the bolts are accessible through the bore (arrow) in the crossmember. | |
Bolt, torque converter to drive plate | |||
35 | Install cap at bottom of torque converter housing | ||
36 | Insert left catalytic converter (4), screw on finger-tight and route electrical lines of oxygen sensor forwards | Transmission 722.685 in model 906.1/2/6/7 with engine 272 | |
Only apply the final tightening torque after the transmission crossmember (2) is installed in order to avoid distortions. | |||
37 | Connect electrical connectors of left oxygen sensor | Transmission 722.685 in model 906.1/2/6/7 with engine 272 | |
38 | Install lines on transmission (1) | ||
Bolt, transmission housing to engine | |||
39 | Attach electrical connector to transmission (1) | ||
40 | Attach rpm sensor to transmission (1) |
| |
Bolt, vehicle speed sensor to transmission housing | |||
41 | Install transfer case. |
| |
42 | Mount propeller shaft to front axle onto transfer case |
| |
43 | Install propeller shaft to rear axle | ||
| Notes on installing propeller shaft | ||
Propeller shaft to transmission | |||
Bolt, rear propeller shaft to front propeller shaft | |||
Nut/bolt, propeller shaft to rear axle/transfer case | |||
44 | Bolt exhaust bracket (3) onto transmission (1) and onto catalytic converter (4) finger-tight | Check rubber mountings and replace if necessary. | |
Model 906.1/2/6/7 with engine 272 with transmission 722.68 | |||
45 | Raise transmission (1) slightly with telescopic lifter | ||
| 000 588 11 62 00 Major assembly mount | ||
46 | Install transmission crossmember (2) together with rear engine mount | Observe identification on transmission crossmember (2). | |
Nut/screw/bolt, transmission carrier to integral carrier/mounting console | |||
Screw/bolt, rear engine mount to transmission | |||
47 | Remove piece of wood for supporting the engine and lower transmission (1) | ||
48 | Bolt on left catalytic converter (4) | Transmission 722.685 in model 906.1/2/6/7 with engine 272 | |
Bolt, catalytic converter to central exhaust system | |||
Bolt, catalytic converter to exhaust manifold | |||
49 | Tighten exhaust bracket (3) on transmission (1) and catalytic converter (4) | Model 906.1/2/6/7 with engine 272 with transmission 722.68 | |
Bolt, bracket to transmission | |||
50 | Install left and right torsion bar holder (5) | Check elastomer bearings and replace if necessary. | |
Bolt, stabilizer bar to frame-type integral support | |||
51 | Lower vehicle | ||
52 | Attach filler pipe to cylinder head | ||
Bolt, filler pipe to cylinder head | |||
53 | Connect ground cable to battery | ||
Danger ! | 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. | |
54 | Pour in automatic transmission fluid and correct oil level | ||
Automatic transmission fluid ATF | |||
Funnel | |||
Dipstick | |||
Hand pump |
Automatic transmission |
Number | Designation | Transmission 722.683/684/ 685/686 | |||
BF27.00-N-1001-01A | Automatic transmission fluid ATF | Filling capacity, first filling | Liter | 7,1 | |
Filling capacity, oil change | Liter | 7,1 | |||
Filling capacity, transmission oil change | with torque converter | Liter | 7,1 | ||
Filling capacity, transmission oil change | without torque converter | Liter | 5,5 | ||
Sheet | - | ||||
Sheet | |||||
Sheet | - | ||||
Sheet | - | ||||
Sheet | - | ||||
906 589 08 63 00
Drain plate
126 589 12 63 00
Funnel
210 589 00 71 00
Hand pump
906 589 00 03 00
Ratchet box wrench
140 589 15 21 00
Dipstick
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