Remove/install transmission with torque converter

AR27.10-P-0500P

Remove/install transmission with torque converter

06.03.2020

Transmission

722.6 in model 203 (except 203.02/05/08/09/22/25/28/29), 209

Transmission

722.9 in model 203.052/054/056/252/254/256/752/756, 209.354/356/372/376/454/456/472/476

Shown on model 203 with transmission 722.6

2

Bolts

20

Ground cable

63

Shift rod

4

Oil pan drain screw

21

Pipeline

63a

Fuse

12

Rear engine cross member

49

Oil cooling line

95

Screw

13

Exhaust bracket

50

Oil cooling line

A

Engine 111.955

17

Front propeller shaft

50a

Screw

B

Except engine 111.955

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 

Remove/install

1

Detach ground line from battery

MODEL 203

AR54.10-P-0003P

Topical note

Notes on battery

AH54.10-P-0001-01A

MODEL 209

AR54.10-P-0003Q

2.1

Remove air filter

ENGINE 111, 112

 Installation: Lightly grease the rubber guides to make assembly easier.

2.2

Remove charge air hose

ENGINE 611, 612

2.3

Remove air filter housing

Model 203 with engine 272 with transmission 722.9
Model 203, 209 with engine 271 with transmission 722.6
Model 203, 209 with engine 646 with transmission 722.6
Model 203.076/276 with engine 113.988 with transmission 722.6
Model 209 with engine 272, 273 with transmission 722.9
Model 209.375/475 with engine 113 with transmission 722.6
Model 209.376/476 as of 4/24/04 with engine 113.987 with transmission 722.6
Model 209.376/476 as of 4/24/04 with engine 113.987 with transmission 722.9

Model 203.076/276 with engine 113.988
Model 209.376/476 as of 4/24/04 with engine 113.987

AR09.10-P-1150AC

Model 203.052/054/056/252/254/256/752/756, 209.354/356/454/456 with engine 272 with transmission 722.9
Model 209 with engine 273 with transmission 722.9

AR09.10-P-1150QB

Model 203 (except 203.02/05/08/09/22/25/28/29), 209 with engine 271 with transmission 722.6

AR09.10-P-1150Q

Model 203 (except 203.02/05/08/09/22/25/28/29), 209 with engine 646 with transmission 722.6

AR09.10-P-1150PM

3

Remove hot film mass air flow sensor

MODEL 203.076/ 276, MODEL 209.376/ 476

AR07.07-P-1454SV

4

Detach filler pipe from engine

5.1

Detach lower engine compartment paneling

Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 111 with transmission 722.6
Model 203 (except 203.02/05/08/09/22/25/28/29), 209 with engine 112 with transmission 722.6
Model 203 (except 203.02/05/08/09/22/25/28/29), 209 with engine 113 with transmission 722.6
Model 203 (except 203.05), 209 with engine 272 with transmission 722.9
Model 209 with engine 273 with transmission 722.9

AR61.20-P-1105P

5.2

Remove bottom sections of soundproofing

Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 611 with transmission 722.6
Model 203 (except 203.02/05/08/09/22/25/28/29), 209 with engine 612 with transmission 722.6
Model 203 (except 203.02/05/08/09/22/25/28/29), 209 with engine 646 with transmission 722.6

AR94.30-P-5300P

6

Drain transmission oil at oil pan

If the transmission oil is burnt or contains wear debris, the oil cooling lines (49, 50) and the oil cooler must be rinsed.



Flush oil line (49, 50) and oil cooler

Transmission 722.9

AR27.55-P-0001PI

Transmission 722.6

AR27.55-P-0001A

7.1

Remove rear exhaust system

Model 203 (except 203.08/28) with engine 112 with transmission 722.6
Model 203 with engine 111 with transmission 722.6
Model 203 with engine 271.921 with transmission 722.6
Model 203 with engine 271.940 with transmission 722.6
Model 203 with engine 271.946 with transmission 722.6
Model 203 with engine 271.948/957 with transmission 722.6
Model 203 with engine 611.962, 612.962 with transmission 722.6
Model 203 with engine 612.990 with transmission 722.6
Model 203, 209 with engine 646 with transmission 722.6
Model 209 with engine 112 with transmission 722.6
Model 209 with engine 113.968 with transmission 722.6
Model 209 with engine 271.940 with transmission 722.6
Model 209 with engine 271.955 with transmission 722.6
Model 209 with engine 612.967 with transmission 722.6
Model 209.376 up to 4/23/04, 209.476 with engine 113.987 with transmission 722.6
Model 209.376 up to 4/23/04, 209.476 with engine 113.987 with transmission 722.9

MODEL 203 with ENGINE 611.962/ 612.962 MODEL 209 with ENGINE 612.967

AR49.10-P-7000PP

MODEL 203, 209 with ENGINE 646

AR49.10-P-7000PM

MODEL 203 with ENGINE 612.990

AR49.10-P-7000PF

MODEL 203, 209 with ENGINE 112 MODEL 209 with ENGINE 113.968 MODEL 209.376 bis 23.4.04 with ENGINE 113.987 MODEL 209.476 with ENGINE 113.987

AR49.10-P-7000PV

MODEL 203 with ENGINE 111

AR49.10-P-7000PR

MODEL 203 with ENGINE 271.921/ 940/ 946/ 948/ 957 MODEL 209 with ENGINE 271.940/ 955

AR49.10-P-7000QK

7.2

Remove complete exhaust system

Model 203 with engine 113.988 with transmission 722.6
Model 203 with engine 272 with transmission 722.9
Model 203, 209 with engine 271.942 with transmission 722.6
Model 209 with engine 272, 273 with transmission 722.9
Model 209.376 as of 4/24/04 with engine 113.987 with transmission 722.6/9

MODEL 203, 209 with ENGINE 271.942

AR49.10-P-7000QD

MODEL 203 with ENGINE 113.988, MODEL 209.376 as of 24.4.2004 with ENGINE 113.987

AR49.10-P-7000AC

MODEL 203 with ENGINE 272, MODEL 209 with ENGINE 272, 273

AR49.10-P-7000QB

8

Remove exhaust manifold with CAT

MODEL 203, 209 with ENGINE 271

Model 203.040/240/740 with engine 271.948 with transmission 722.6
Model 203.042/242/742, 209.342/442 with engine 271.940 with transmission 722.6
Model 203.043/243/743, 209.343 with engine 271.942 with transmission 722.6
Model 203.046/246/746 with engine 271.946 with transmission 722.6
Model 203.730 with engine 271.921 with transmission 722.6
Model 203.741 with engine 271.957 with transmission 722.6
Model 209.341/441 with engine 271.955 with transmission 722.6

AR14.10-P-4095QK

9

Support transmission using telescopic lifter and transmission plate



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

10

Remove rear engine cross member (12) with engine mount

Model 203 (except 203.02/05/08/09/22/25/28/29), 209 with transmission 722.6
Model 203.052/054/056/252/254/256/752/756, 209.354/356/372/376/454/456/472/476 with transmission 722.9

Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 111 with transmission 722.6
Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 112 (except 112.916/953) with transmission 722.6
Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 113 with transmission 722.6
Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 271 with transmission 722.6
Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 646 with transmission 722.6
Model 209 with engine 112 with transmission 722.6
Model 209 with engine 113 with transmission 722.6
Model 209 with engine 271 with transmission 722.6
Model 209 with engine 646 with transmission 722.6
Model 209.376/476 with engine 113 with transmission 722.9

AR22.10-P-1160PR

Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 611.962 with transmission 722.6
Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 612.962 with transmission 722.6
Model 203 (except 203.02/05/08/09/22/25/28/29) with engine 612.990 with transmission 722.6
Model 209.316 with engine 612.967 with transmission 722.6

AR22.10-P-1160HC

Model 203.052/252/752 with engine 272.920 with transmission 722.9
Model 203.054/254, 209.354/454 with engine 272.940 with transmission 722.9
Model 203.056/256/756, 209.356/456 with engine 272.960 with transmission 722.9
Model 209.372/472 with engine 273 with transmission 722.9

AR22.10-P-1160QB

 Do not detach engine mount from rear engine cross member (12).

11

Disconnect front propeller shaft section (17) from transmission

AR41.10-P-0050-02EA

 The flexible coupling remains on the front propeller shaft (17).

When installing propeller shaft:



Mount front propeller shaft to transmission

AR41.10-P-0050-07EA

 Self-locking nut, flexible coupling to transmission or front propeller shaft

*BA41.10-P-1001-01A

 Torque wrench

*001589662100

12

Release pilot bushing from flexible coupling and push back front propeller shaft (17)

AR41.10-P-0050-09DA

If pilot bushing is seized



Prepare drift to release pilot bushing in flexible couplings.



Drift for releasing the fitting sleeves in the flexible couplings

WF58.50-P-4110-01A

13

Detach shift rod (63) from below at intermediate lever



Transmission 722.9 in model 203.052/054/056/252/254/256/752/756, 209.354/356/372/376/454/456/472/476

BT27.60-P-0021-01A

 Observe lock washer variant.

14

Disconnect plug connector

Transmission 722.6 (except 722.649) in model 203 (except 203.02/05/08/09/22/25/28/29), 209

AR27.10-P-0500-01A

TRANSMISSION 722.9

AR27.40-P-0700-01V

 Bolt, heat shield to transmission housing

*BA27.40-P-1014-01A

 Bolt, leaf spring to transmission housing

*BA27.40-P-1019-01A

15.1

Unclip cover and remove bolts (95)

TRANSMISSION 722.6/9 except TRANSMISSION 722.9 with angled threaded connection

 Bolt, torque converter to driver spider

*BA27.20-P-1002-01C

15.2

Unclip cover from transmission bell housing and remove bolts (95)

Transmission 722.9 with angled threaded connection

AR27.20-P-0100-01A

 Bolt, torque converter to driver spider

*BA27.20-P-1002-01C

 Socket wrench bit

*001589650900

 Long wedge

*115589035900

16

Unscrew pipeline (21) from oil pan

 ENGINE 272, 273Screw/bolt, oil line bracket to oil pan

*BA01.45-P-1007-01M

 ENGINE 111, 611, 612Bolt, oil pan to cylinder crankcase

*BA01.45-P-1001-01A

 ENGINE 112, 113 (except 113.994)Bolt, oil pan to cylinder crankcase

*BA01.45-P-1001-01B

 ENGINE 271Bolt, oil pan to cylinder crankcase

*BA01.45-P-1001-01H

 ENGINE 646Bolt, oil pan to cylinder crankcase

*BA01.45-P-1001-01G

17.1

Detach oil cooling line (49) to oil cooler from transmission

ENGINE 111, 112, 113, 271, 272, 273


Before starting work, the area around the oil cooling lines (49) must be thoroughly cleaned in the area around the connecting points on the transmission.
Even the smallest dirt particles in the hydraulic components can lead to malfunctions and a total failure of the transmission.

17.2

Detach oil cooling lines (50) to oil cooler

ENGINE 611, 612, 646


Before starting work, the area around the oil cooling lines (50) must be cleaned thoroughly at the connecting points on the transmission.
Even the smallest dirt particles in the hydraulic components can lead to malfunctions and a total failure of the transmission.

18

Slacken bolt (50a)

ENGINE 611, 612, 646

19

Remove screw/bolts (2)

 TRANSMISSION 722.6Bolt, automatic transmission to engine

*BA27.40-P-1008-01A

 TRANSMISSION 722.9Bolt, automatic transmission to engine

*BA27.40-P-1008-01A

20

Turn pipeline (21) downwards

21

Remove transmission downwards at an angle using telescopic lifter and transmission plate

 Secure torque converter to prevent it from falling out.

22

Take out torque converter with grab handles

If necessary

TRANSMISSION 722.6

AR27.20-P-0500-01P

TRANSMISSION 722.9

AR27.20-P-0500-01W

TRANSMISSION 722.602/615/616/618/633/634/636/640/641/642/649/695/696/698/699Installation height of torque converter

*BE27.20-P-1001-01B

TRANSMISSION 722.9Installed height of torque converter

*BE27.20-P-1001-01E

Multi-purpose paste

*BR00.45-Z-1009-06A

 Handles

*168589006200

 Parallel rest

*126589043100

23

Remove corrosion from crankshaft

AR03.20-P-1000-01A

Assembly cleaner

*BR00.45-Z-1028-04A

Multi-purpose paste

*BR00.45-Z-1009-06A



Check

24

Check threaded unions in driven plate spider or torque converter

 If the threaded unions are damaged or loose, the driven plate spider or the torque converter must be replaced.

25

Install in the reverse order

26

Perform basic programming

MODEL 203

AR00.19-P-0200P

MODEL 209

AR00.19-P-0200Q

27

Check transmission oil level and correct if necessary

TRANSMISSION 722.6

AR27.00-P-0100AC

TRANSMISSION 722.9

AR27.00-P-0270W

28

Read out fault memory and erase if necessary



AD00.00-P-2000-04A

29

Perform transmission adaptation using diagnostic system

After replacement or repair of transmission

30

Reset data on service life of torque converter lockup clutch using diagnostic system

After replacing torque converter

 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

31

Perform engine test run and check transmission for proper function and leak tightness

Check values for torque converter

Number

Designation

Transmission 722.600/601/602/603/604/605/608/611/614/615/616/619/626/629/634/637/638/640/642/660/661/695/699

Transmission 722.606/607/609/617/618/623/624/628/630/631/632/633/636/641/643/645/662/663/664/665/666/667/668/669/672/674/675/676/690/696/698

BE27.20-P-1001-01B

Installation height of torque converter

Distance from transmission housing

mm

7 (-2)

19,5 (-2)

Check values for torque converter

Number

Designation

Transmission 722.649

BE27.20-P-1001-01B

Installation height of torque converter

Distance from transmission housing

mm

20 (-2)

Test values for torque converter

Number

Designation

Transmission 722.9

BE27.20-P-1001-01E

Installed height of torque converter

Distance, bolt flange to transmission housing flange

Helical screwed connection

mm

9,5

See picture

AR27.20-P-0500-01W

Axial screwed connection

mm

19,5

 Oil pan

Number

Designation

Engine 111.951/955/958

Engine 111.92/94/952/956/957/96/97/98

BA01.45-P-1001-01A

Bolt, oil pan to cylinder crankcase

M6

Nm

8

10

M8

Nm

20

25

M10

Nm

–

–

 Oil pan

Number

Designation

Engine 611.960/961/962

ENGINE 612.961/962/963/965/966 ENGINE 613.961

BA01.45-P-1001-01A

Bolt, oil pan to cylinder crankcase

M6

Nm

9

9

M8

Nm

20

20

M10

Nm

–

–

 Oil pan

Number

Designation

Engine 612.967

Engine 612.990

BA01.45-P-1001-01A

Bolt, oil pan to cylinder crankcase

M6

Nm

9

9

M8

Nm

20

20

M10

Nm

–

–

 Oil pan

Number

Designation

Engine 112.910/ 911/912/913/914/ 915/917/920/921/ 922/923/940/941/ 942/943/944/945/ 946/947/949/951/ 954/955/960/961/ 970/972/973/976

Engine 113.940/ 941/942/943/944/ 960/961/962/963/ 965/967/968/969/ 980/981/982/984/ 986/992/995

BA01.45-P-1001-01B

Bolt, oil pan to cylinder crankcase

M6

Nm

9

9

M8

Nm

20

20

 Oil pan

Number

Designation

Engine 113.987/988/991

BA01.45-P-1001-01B

Bolt, oil pan to cylinder crankcase

M6

Nm

9

M8

Nm

20

 Oil pan

Number

Designation

Engine 646.951/961/962/963/966

BA01.45-P-1001-01G

Bolt, oil pan to cylinder crankcase

M6

Nm

9

M8

Nm

20

M10

Nm

–

 Oil pan

Number

Designation

Engine 271

BA01.45-P-1001-01H

Bolt, oil pan to cylinder crankcase

M630

Nm

9

M690

Nm

9

M835

Nm

20

 Oil pan

Number

Designation

Engine 272

Engine 273

BA01.45-P-1007-01M

Screw/bolt, oil line bracket to oil pan

M6

Nm

9

9

 Torque converter

Number

Designation

Transmission 722.6 (except 722.648)

Transmission 722.9

BA27.20-P-1002-01C

Bolt, torque converter to driver spider

Straight threaded connection

M8

Nm

42

42

Angled threaded connection

Stage 1

Nm

4

4

Stage 2

Nm

30

30

Stage 3

°

90

90

 Housing

Number

Designation

Transmission 722.6 (except 722.660/661/662/663/666/673/674)

Transmission 722.9

BA27.40-P-1008-01A

Bolt, automatic transmission to engine

M1040

Nm

39

38

M1045

Nm

–

38

M1090

Nm

39

38

M12

Nm

–

–

 Housing

Number

Designation

Transmission 722.6 (except 722.660/661/662/663/666/673/674)

Transmission 722.9

BA27.40-P-1014-01A

Bolt, heat shield to transmission housing

Nm

11

9

 Housing

Number

Designation

Transmission 722.6 (except 722.660/661/662/663/666/673/674)

Transmission 722.9

BA27.40-P-1019-01A

Bolt, leaf spring to transmission housing

Nm

8

5

 Propeller shaft

Number

Designation

Model 203

Model 209

BA41.10-P-1001-01A

Self-locking nut, flexible coupling to transmission or front propeller shaft

M10

Nm

40

40

M12

Nm

60

60

Repair materials

Number

Designation

Order number

BR00.45-Z-1009-06A

Multi-purpose paste

A 000 989 80 51

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01