Remove/install transmission with torque converter

AR27.10-P-0500T

Remove/install transmission with torque converter

7.2.12

 

Remove/install



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



Before starting work the area around the oil cooler lines (10) must be thoroughly cleaned in the area around the separation points. Even the smallest dirt particles, introduced into the hydraulic components, can lead to malfunctions and a total failure of the transmission

1

Move selector lever into position "N"

2

Disconnect battery ground cable

Model 211.0/6

AR54.10-P-0003T

Model 211.2

AR54.10-P-0003TA

3.1

Remove air filter housing

Engine 112, 113 except 113.967

AR09.10-P-1150SVK

Engine 628

AR09.10-P-1150TD

Engine 113.967

3.2

Pull engine cover upwards off the cylinder head cover

Engine 271

3.3

Remove cylinder head cover trim

Engines 646, 647

AR01.20-P-5014-02A



*BA01.20-P-1002-01G



*BA01.20-P-1003-01G

Engine 648

AR01.20-P-5014-02C



*BA01.20-P-1002-01G



*BA01.20-P-1003-01G

4

Remove bolt (1a) of oil filler pipe (1)



*BA27.10-P-1005-03A

5.1

Remove bottom section of soundproofing

Vehicles with diesel engine

AR94.30-P-5300T

5.2

Remove bottom engine compartment paneling

Vehicles with gasoline engine

AR61.20-P-1105T

6

Remove oil drain screw from the transmission oil pan and drain transmission oil

If necessary

 If there are metal shavings in the transmission oil, the transmission oil must be drained. The torque converter (15) must be replaced. Metal chips can cause transmission damage.

 If the transmission oil is burnt or interspersed with abrasive particles, the oil cooler lines (10) and oil cooler must be flushed out.

AR27.55-P-0001A

 Only flush torque converter (15) with automatic transmission fluid.

 Installation: Install new sealing ring.



*BA27.10-P-1001-03A

7

Remove bracket (2) for bottom section of soundproofing at rear

Vehicles with diesel engine

8

Remove rear right bracket of rear bottom part of noise encapsulation

Engine 628

9.1

Remove exhaust manifold with catalytic converter

Engine 271

AR14.10-P-4095TK

9.2

Remove both catalytic converters

Engine 628

AR49.10-P-5500TD

10

Remove bracket (3)

 Engine 112, 113, 628: Remove left and right bracket (3)

 Check rubber mount on bracket (3) for wear and replace if necessary.

Engine 628:



*BA49.10-P-1001-01H



*BA49.10-P-1012-01H

Engine 646, 647:



*BA49.10-P-1001-01I



*BA49.10-P-1002-01I

Engine 648:



*BA49.10-P-1008-01I



*BA49.10-P-1009-01I

Engines 112, 113:



*BA49.10-P-1012-01A



*BA49.10-P-1011-01A

Engine 271:



*BA49.10-P-1004-01K



*BA49.10-P-1005-01K

11

Detach locking clip (5) and unhook selector lever rod (4) from transmission

 Replace locking clip (5).

12

Detach ground line (6) from transmission



*BA27.40-P-1013-01A

13

Detach heat shield (7) from transmission



*BA27.40-P-1014-01A

14

Disconnect connector of electronic transmission control (X22/19)

15

Detach cover (8)

16

Remove bolts (9) of torque converter (15) from driven plate

 Do not rotate the engine opposite to the direction of rotation of the engine, the timing chain may skip a tooth.

 Engine 112, 113, 271, 646, 647, 648: Use socket to turn engine at the center bolt of the crankshaft in the direction of engine rotation until the bolts (9) are accessible through the cutout in the engine oil pan.

 Engine 628:

Turn the engine at the torque converter (15) in the direction of engine rotation until the bolts (9) are accessible through the cutout in the engine oil pan: 

Crank engine on the torque converter (15).

AR01.00-P-0100M



*BA27.20-P-1002-01C



*001589650900

17

Detach oil cooling lines (10) from transmission housing

 Installation: Replace sealing rings.



*BA27.55-P-1002-01B

18

Detach retaining clamps of oil cooling lines (10) from engine oil pan and place oil cooling lines (10) to one side

 Do not bend or kink oil cooling lines (10).



*BA27.55-P-1008-01B

19

Support transmission with transmission jack and transmission plate

20

Detach rear engine cross member (11) with rear engine mount (12)

except engine 628

AR22.10-P-1160T

Engine 628

AR22.10-P-1160TD

21

Detach propeller shaft (13) from transmission and pull backwards

 The flexible coupling remains on the propeller shaft (13).

AR41.10-P-0050-02T



*BA41.10-P-1001-01A

 Installation: Mount propeller shaft (13) on transmission

AR41.10-P-0050-07I



*BA41.10-P-1001-01A

22

Lower transmission slightly and lash it securely to transmission platform

23

Use suitable tool to support engine at engine oil pan

 When removing the transmission the engine must not tilt against the splash wall, as otherwise the brake pipes which are routed there will be damaged.

24

Detach transmission from crankcase or from the engine oil pan

 Place starter to the side with lines connected and secure to prevent it falling down.



*BA27.40-P-1008-01A

25

Remove bolt (1b) on oil filler pipe (1) one revolution



*BA27.10-P-1004-03A

26

Pull oil filler pipe (1) out of transmission and put down to one side

 Installation: Replace O-ring.

27

Detach transmission from crankcase and remove downwards at an angle

 Secure torque converter (15) to prevent it from falling out.

 Installation: Align bolt holes in torque converter (15) with the holes in the driven plate.

28

Remove torque converter (15) with grab handles

If necessary

AR27.20-P-0500-01B

Installed height of torque converter

*BE27.20-P-1001-01B



*168589006200



*210589007100

Multipurpose paste

*BR00.45-Z-1009-06A

29

Install in the reverse order

30

Check oil level in automatic transmission, correct if necessary

AR27.00-P-0100AC

31

Read out fault memory with STAR DIAGNOSIS and erase if necessary

32

Perform transmission adaptation

After replacing or repairing transmission, perform transmission adaptation.

33

Perform engine test run and check transmission for proper function and leaktightness.

Number

Designation

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

Installed height of torque converter

Distance from transmission housing

mm

7 (-2)

19.5 (-2)

Number

Designation

Transmission
722.635/639/
644

BE27.20-P-1001-01B

Installed height of torque converter

Distance from transmission housing

mm

21 (-2)

Number

Designation

Engine
646.951/961,
647.961

Engine
648

BA01.20-P-1002-01G

Bolt, cylinder head cover trim to cylinder head

Nm

9

9

BA01.20-P-1003-01G

Bolt, cover to charge air manifold.

Nm

9

9

Number

Designation

Model
211

BA41.10-P-1001-01A

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

M10

Nm

40

M12

Nm

60

Number

Designation

Trans-mission 722.6 except 722.628/
648/649

BA27.10-P-1001-03A

Oil drain screw to oil pan

Nm

20

BA27.10-P-1004-03A

Bolt, oil filler pipe to transmission housing

Nm

8

BA27.10-P-1005-03A

Bolt, oil filler pipe to heat shield

Nm

8

Number

Designation

Trans-mission 722.6
except
722.648

BA27.20-P-1002-01C

Bolt, torque converter to drive plate

Straight threaded connection

M8

Nm

42

Angled threaded connection

Stage 1

Nm

4

Stage 2

Nm

30

Stage 3

°

90

Number

Designation

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

BA27.40-P-1008-01A

Bolt, automatic transmission to engine

M1040

Nm

39

M1090

Nm

39

M12

Nm

-

BA27.40-P-1013-01A

Bolt, ground line to transmission housing

Nm

20

BA27.40-P-1014-01A

Bolt, heat shield to transmission housing

Nm

11

Number

Designation

Trans-mission 722.6 in model 211

BA27.55-P-1002-01B

Banjo bolt or union nut, oil cooler line to torque converter and transmission housing

Stage 1

Nm

5

Stage 2

°

90

Hexalobular bolt

Nm

-

BA27.55-P-1008-01B

Bolt, oil cooler line retaining clamp to oil pan

Nm

8

Number

Designation

Engine
112, 113
in model
211

BA49.10-P-1011-01A

Bolt of three way catalytic converter bracket to transmission housing

Nm

20

BA49.10-P-1012-01A

Self-locking nut of catalytic converter bracket to three way catalytic converter

Nm

20

Number

Designation

Engine
628.961

BA49.10-P-1001-01H

Nut, support for exhaust bracket to transmission

Nm

20

BA49.10-P-1012-01H

Nut, carrier to exhaust pipe

Nm

20

Number

Designation

Engine
646.8

Engine
646.951/
961/962/
963/966 without code 474

Engine
646.951/
961/962/
963/966 will
Code 474

Engine
647

BA49.10-P-1001-01I

Self-locking nut of catalytic converter bracket to three way catalytic converter

Nm

20

20

20

20

BA49.10-P-1002-01I

Bolt of three way catalytic converter bracket to transmission housing

Nm

20

20

20

20

Number

Designation

Engine 648.961

BA49.10-P-1008-01I

Self-locking nut, bracket to front exhaust system

Nm

20

BA49.10-P-1009-01I

Bolt, bracket to transmission housing

Nm

20

Number

Designation

Engine
271
in model 211

BA49.10-P-1004-01K

Nut connecting front exhaust system to bracket

Nm

20

BA49.10-P-1005-01K

Bolt connecting bracket for front exhaust system to transmission

Nm

20

Number

Designation

Order number

BR00.45-Z-1009-06A

Multipurpose paste

A 000 989 80 51 10