Remove/install intelligent servo module

AR27.19-P-0550EW

Remove/install intelligent servo module

19.3.15

TRANSMISSION

722.9 in MODEL 212, 218

1

Transmission

4

Bolts

7

Bolts

2

Engine cross member

5

Engine mount

10

Bolts

3

Range selector shaft

6

Exhaust bracket

A80

Intelligent servo module for DIRECT SELECT

 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



Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 

Remove/install

1

Release parking brake

2

Disconnect battery ground line

AR54.10-P-0003EW



Notes on battery

AH54.10-P-0001-01A

3.1

Remove engine compartment paneling

TRANSMISSION 722.9 in MODEL 212 with ENGINE 156
TRANSMISSION 722.9 in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 in MODEL 212 with ENGINE 273
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 157
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 274
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 276
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 278

AR61.20-P-1105EW

3.2

Remove bottom sections of soundproofing

MODEL 212, 218 with ENGINE 642 with TRANSMISSION 722.9
MODEL 212, 218 with ENGINE 651 with TRANSMISSION 722.9

AR94.30-P-5300EW

4

Support and secure transmission (1)



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B


Secure transmission (1) with tensioning strap.
Otherwise the transmission (1) may be damaged by it slipping off or tilting over.

5

Remove rear engine cross member (2)

TRANSMISSION 722.9 in MODEL 212, 218

TRANSMISSION 722.9 in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 in MODEL 212 with ENGINE 273
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 157
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 274
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 276
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 278
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 642
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 651

AR22.10-P-1180CW

TRANSMISSION 722.9 in MODEL 212 with ENGINE 156

AR22.10-P-1180CMG

6

Mark position of front flexible coupling relative to output flange and propeller shaft


The marking is necessary to ensure that the factory installation position can be restored again when installed.
Otherwise the drive line may suffer from vibrations.

7

Mark vibration damper

TRANSMISSION 722.9 in MODEL 212 with ENGINE 272.983

 Attach colored identification of vibration damper position relative to flexible coupling and propeller shaft, to enable the ex-factory installation position to be restored again during installation.

8

Detach drive shaft at transmission (1)

AR41.10-P-0050EW

9

Remove exhaust bracket (6) from transmission (1)



TRANSMISSION 722.9 in MODEL 212 with ENGINE 156
TRANSMISSION 722.9 in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 157
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 276
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 278
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 642
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 651
TRANSMISSION 722.9 in MODEL 212.090

*BA49.10-P-1023-01AE



TRANSMISSION 722.9 in MODEL 212 with ENGINE 156
TRANSMISSION 722.9 in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 157
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 276
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 278
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 642
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 651
TRANSMISSION 722.9 in MODEL 212.090

*BA49.10-P-1024-01AE

10

Detach EGR lines from catalytic converters

TRANSMISSION 722.9 in MODEL 212 with ENGINE 272.983

AR14.20-P-1020-01EWD

 Bolt, clamp for exhaust gas recirculation line to catalytic converter

*BA49.10-P-1041-01AE

11

Remove catalytic converters from exhaust manifold

TRANSMISSION 722.9 in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 in MODEL 212 with ENGINE 273
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 276
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 278



TRANSMISSION 722.9 in MODEL 212 with ENGINE 272.983

*BA49.10-P-1001-01AE

12

Remove front exhaust pipe from diesel particulate filter

TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 642

 Bolt, pipe clamp to diesel particulate filter

*BA49.10-P-1020-01AE

13

Detach electrical connector from Intelligent servo module for DIRECT SELECT (A80)

14

Lower transmission (1) slightly


When being lowered the engine must not rest on the front axle carrier.
Otherwise, the oil pan may be damaged.

15

Remove bolts (10) from intelligent servo module for DIRECT SELECT (A80).

 Installation: Replace bolts (10).

 Standard bolt/hexagon-spacer bolt, shift module (ISM) to transmission housing

*BA27.40-P-1021-01A

16

Remove intelligent servo module for DIRECT SELECT (A80) with bleed hose


When reusing the intelligent servo module for DIRECT SELECT (A80) do not detach the vent hose.
Otherwise there may be leakages in the connecting points, with resulting water entry.

 Installation: When replacing the intelligent servo module for DIRECT SELECT (A80), the vent hose must be replaced.
The positions of the range selector shaft (3) and the intelligent servo module for DIRECT SELECT (A80) must line up.

 Assembly tool

*722589030900

17

Rotate range selector shaft (3) of transmission (1) in counterclockwise direction up to the end stop at position "D" (arrow 1 picture)

When reusing the intelligent servo module for DIRECT SELECT (A80)

 New intelligent servo module for DIRECT SELECT (A80) set to position "D" (arrow 2 picture) (condition as supplied).

18

Install in the reverse order

19

Connect diagnostic system, read out fault memory and conduct initial startup of the intelligent servo module for DIRECT SELECT (A80)

When reusing the intelligent servo module for DIRECT SELECT (A80)



AD00.00-P-2000-04A

 Housing

Number

Designation

TRANSMISSION 722.9

BA27.40-P-1021-01A

Standard bolt/hexagon-spacer bolt, shift module (ISM) to transmission housing

Stage 1

Nm

4

Stage 2

°

90

 Exhaust system

Number

Designation

ENGINE 156, 157, 271, 272, 273, 276, 278 in MODEL 212

BA49.10-P-1001-01AE

Bolt, catalytic converter to exhaust manifold

Nm

20

 Exhaust system

Number

Designation

ENGINE 642, 651 in MODEL 212

ENGINE 642, 651 in MODEL 218

BA49.10-P-1020-01AE

Bolt, pipe clamp to diesel particulate filter

Nm

35

35

 Exhaust system

Number

Designation

ENGINE 156, 157, 271, 272, 273, 276, 278 in MODEL 212

ENGINE 157, 276, 278 in MODEL 218

BA49.10-P-1023-01AE

Bolt, exhaust system bracket to transmission

Nm

20

20

 Exhaust system

Number

Designation

ENGINE 642, 651 in MODEL 212

ENGINE 642, 651 in MODEL 218

BA49.10-P-1023-01AE

Bolt, exhaust system bracket to transmission

Nm

20

20

 Exhaust system

Number

Designation

ENGINE 156, 157, 271, 272, 273, 276, 278 in MODEL 212

ENGINE 157, 276, 278 in MODEL 218

BA49.10-P-1024-01AE

Bolt/nut, exhaust system bracket to exhaust system

Nm

20

20

 Exhaust system

Number

Designation

ENGINE 642, 651 in MODEL 212

ENGINE 642, 651 in MODEL 218

BA49.10-P-1024-01AE

Bolt/nut, exhaust system bracket to exhaust system

Nm

20

20

 Exhaust system

Number

Designation

ENGINE 156, 157, 271, 272, 273, 276, 278 in MODEL 212

BA49.10-P-1041-01AE

Bolt, clamp for exhaust gas recirculation line to catalytic converter

Nm

9