Remove/install automatic transmission

AR27.10-P-0502RFH

22.11.2019

Transmission

724.2 in model 205 with engine 651

P27.10-2552-09

1	Transmission	10	Cover	28	High-voltage electrical line
3	Heat shield	10a	Screw	29	3-phase high-voltage lines
4	Electrical connector	11	Bracket	29a	High-voltage plug
9	Bracket	11a	Screw	A79/1b1	Electric machine temperature sensor

1	Transmission
1a	Screw
12	Transmission input shaft

P27.00-2445-11

6	Oil lines
41	Ground cables

P27.10-2553-11

13	Bracket
14	Screw

P54.10-4166-11

 Danger	Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)	Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.	AS00.00-Z-0035-01A
 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 self-locking nuts and bolts		AH00.00-N-0001-01A
Topical note	General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system		AH00.00-Z-0300-01A
Topical note	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
Topical note	Notes on battery		AH54.10-P-0001-01A
	Notes on automatic transmission		AH27.19-P-0001-01NKB
 	Remove/install
1	Move selector lever into position "N"
2	Release parking brake
3	Perform disable for the high-voltage on-board electrical system		AR54.10-P-1150LW
4	Detach ground line of on-board electrical system battery		AR54.10-P-0003LW
5	Secure vehicle on vehicle lift		AR00.60-P-0100CW
6	Detach high-voltage electrical line (28) from A/C compressor and expose
7	Remove center engine compartment paneling and rear engine compartment paneling and their brackets under transmission (1)		AR61.20-P-1105LW
8	Expose high-voltage electrical line (28) downwards
9	Detach and unclip ground lines (41) from transmission (1)
10	Remove catalytic converter		AR49.10-P-7100LWB
11	Remove heat shield(3)		AR27.40-P-0700-01LF
12	Unlock electrical connector (4) at electrohydraulic controller unit, disconnect and unclip electrical line from transmission (1)
13	Detach oil lines (6) from transmission (1) and oil pan, seal using suitable stop plugs and set aside	 Bolt, oil line to transmission	*BA27.10-P-1009-04G
		 Bolt, bracket for oil line to transmission	*BA27.10-P-1010-04G
		 Bolt, oil line bracket to oil pan	*BA27.10-P-1011-04G
		 Record plug	*129589009100
14	Support transmission (1) using major assembly mount and support plate, and lash down securely
	000 588 10 62 00 Support plate		WS26.00-P-3309B
	000 588 11 62 00 Major assembly mount		WS01.00-P-0092B
15	Remove rear engine cross member with rear engine mount		AR22.10-P-4360LWB
		 Never use impact wrench or compressed air tools for screwing in or unscrewing the bolts! Otherwise the threads can get damaged.
16	Remove bolt (14) and unclip bracket (13) from transmission (1)	 Bolt, hoop guard to transmission	*BA08.10-P-1002-01F
17	Use color to mark front flexible coupling relative to output flange and drive shaft and remove
	Drift for releasing the fitting sleeves in the flexible couplings		WF58.50-P-4110-01A
			AR41.10-P-0040-01LW
		 Flex disk or joint flange at transmission/rear axle differential or propeller shaft	*BA41.10-P-1001-01L
		 Counterholder	*176589004000
18	Carefully lower transmission (1) slightly
19	Release, detach and expose electrical connection from temperature sensor on electrical machine (A79/1b1)
20	Detach bracket (9) from transmission (1)	 Screw/bolt, bracket for electrical lines to transmission housing	*BA27.10-P-1027-04G
21	Remove bolt (10a) and remove cover (10)	 Model 205.0/2 with engine 651 with transmission 724.2 with code ME04 (Mild hybrid drive)Bolt, hoop guard to transmission	*BA08.10-P-1002-01F
22	Remove bolt (11a) from bracket (11)	 Model 205.0/2 with engine 651 with transmission 724.2 with code ME04 (Mild hybrid drive)Bolt, 3-phase high-voltage line to electrical machine housing	*BA08.10-P-1003-01F
23	Detach high-voltage plug (29a) of 3-phase high-voltage lines (29) from electrical machine and place at right, next to the transmission (1)	 Cover up high voltage plug (29) and handle carefully. Otherwise the high voltage on-board electrical system may be damaged.
		 The bolt for the high-voltage connector (29a) acts as an extraction and insertion aid, and it is integrated into the high-voltage connector (29a).
		 Model 205.0/2 with engine 651 with transmission 724.2 with code ME04 (Mild hybrid drive)Bolt, 3-phase high-voltage line coupling connector to electrical machine housing	*BA08.10-P-1001-01F
24	Unclip high-voltage electrical line (28) and hang over transmission (1) to right and at one side
25	Detach starter from transmission (1)		AR15.30-P-7100LWY
		 Secure starter against falling. Damage will otherwise occur.
26	Unscrew bolts (1a) and remove transmission (1) from below	 Installation: Apply some anticorrosion grease to the collar and gearing of the transmission input shaft (12).
		 Bolt/nut, transmission to engine	*BA27.10-P-1001-04G
		Anticorrosion grease 40 g / DB supply specification 6834.00	*BR00.45-Z-1006-06A
27	Install in the reverse order
28	Perform transmission adaptation using diagnostic system	After replacing the transmission (1) or the electrical machine rotor position sensor or the electrical machine.
			AD00.00-P-2000-04B
	Check
29	Check oil level in transmission (1) and correct		AR27.00-P-0270EH
 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
30	Test run engine and check transmission (1) for leaktightness and proper operation

 Electric motor

Number	Designation		Model 205.0/2 with code ME04 (Mild hybrid drive)
BA08.10-P-1001-01F	Bolt, 3-phase high-voltage line coupling connector to electrical machine housing	Nm	10

 Electric motor

Number	Designation		Model 205 with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))	Model 205.0/2 with code ME04 (Mild hybrid drive)
BA08.10-P-1002-01F	Bolt, hoop guard to transmission	Nm	9	15

 Electric motor

Number	Designation		Model 205 with code ME06 (Hybrid drive 60 kW variant (incl. plugin))
BA08.10-P-1002-01F	Bolt, hoop guard to transmission	Nm	15

 Electric motor

Number	Designation		Model 205.0/2 with code ME04 (Mild hybrid drive)
BA08.10-P-1003-01F	Bolt, 3-phase high-voltage line to electrical machine housing	Nm	16