Detach/attach transmission housing on torque converter housing.

AR27.50-P-0601W

Detach/attach transmission housing on torque converter housing.

18.02.2020

Transmission

722.9, 724.2

Shown on transmission 722.9 except code M005 (4MATIC)

1

Transmission housing

6

B2 multidisk brake

1d

Seal

11w

Screws (15 pcs.)

1h

Rear bracket, engine mount

12w

Screws (2 pcs.)

1l

Deep-groove ball bearing

20

Output flange

1r

Radial shaft sealing ring

24

Output shaft

1w

Torque converter housing

34

Oil filter

3

Oil pan

H

Valve lifter

4

Electrohydraulic controller unit

P1

Support plate

5

Clutch pack BR

Example illustration with code M005 (4MATIC)

1

Transmission housing

22

Connecting flange

19

Bolts

23

Collar nut

21

Intermediate housing

 Caution

Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil

Wear protective gloves, protective clothing and safety glasses.
Do not pour transmission oil into beverage bottles.

AS00.40-Z-0001-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Notes on threaded connections with aluminum screws/bolts

AH00.00-P-0006-01RM

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on automatic transmission

AH27.19-P-0001-01NKB

Remove

1

Fasten transmission onto assembly stand.



000 588 00 31 00 Assembly stand for cars

Transmission 724.2

WS01.00-N-3028B

Transmission 722.9

AR27.10-P-0600-01W

Transmission 724.2

AR27.10-P-0600-01EH

 Transmission 724.2
Assembly device

*724589044000

 Transmission 722.9
Assembly stand

*116589065900

 Transmission 722.9
Mounting plate

*140589346300

 Transmission 724.2
Lifting device

*724589026300

2

Remove electric machine.

Transmission 724.2

AR08.10-P-0012EH

3

Remove electrohydraulic controller unit  (4).

Transmission 722.9

AR27.19-P-0200W

Transmission 724.2

AR27.19-P-0200EH

4.1

Remove output flange (20).

Transmission 722.9 (except 722.96) in model 204, 207, 216, 221
Transmission 722.9 (except 722.96/97) in model 205, 212, 217, 218, 222
Transmission 722.9 in model 166.058, 171, 172, 203, 209, 211, 215, 219, 220, 230, 231
Transmission 722.9 in model 251.021/026/054/056/126/154/156
Transmission 722.9 in model 463
Transmission 724.2

AR27.50-P-0620-02W

 Socket wrench bit

*126589020900

 Pin wrench

*129589010700

 Puller, two-arm

*000589883300

4.2

Remove transfer case.

Transmission 722.9 in model 164, 166 (except 166.058), 251 (except 251.021/026/054/056/126/154/156), 292
Transmission 722.96 in model 204, 216, 221
Transmission 722.96 in model 207.3 with engine 276
Transmission 722.96/97 in model 205, 212, 217, 218, 222

Transmission 722.9 in model 164

AR28.10-P-0100GZ

Transmission 722.9 in model 251.020/022/065/072/075/077/122/157/165/172/175/177

AR28.10-P-0100RT

Transmission 722.9 in model 166 (except 166.058), 292

AR28.10-P-0100GQ

Transmission 722.96/97 in model 205

AR28.10-P-1004LWY

Transmission 722.96/97 in model 217, 222

AR28.10-P-1004LFX

Transmission 722.96 in model 204 with engine 272
Transmission 722.96 in model 204 with engine 642
Transmission 722.96 in model 204 with engine 651
Transmission 722.96 in model 204, 207.38 with engine 276
Transmission 722.96 in model 204.9 with engine 274

AR28.10-P-1004CWX

Transmission 722.96/97 in model 212, 218

AR28.10-P-1004EW

Transmission 722.96 in model 216, 221

AR28.10-P-1004SYZ

4.3

Remove adapter housing.

Transmission 722.9 in model 166.058, 251.021/026/054/056/126/154/156

Transmission 722.9 in model 251.026/054/056/126/154/156

AR27.30-P-0800RT

Transmission 722.9 in model 166.058

AR27.30-P-0800GQ

5

Unscrew screws (19) and remove intermediate housing (21) from transmission housing (1).

Transmission 722.9 in model 164, 166, 251, 292

6

Unscrew collar nut (23) and remove connecting flange (22).

Transmission 722.9 in model 164, 166, 251, 292

7

Remove radial shaft sealing ring (1r) with a suitable tool.


Do not damage the seat of the radial shaft sealing ring (1r).
Otherwise leaks may occur.

8

Remove deep-groove ball bearing (1l).

AR27.50-P-0601-01A

 Puller

*001589503300

 Collet chuck

*140589063400

9

Take out shim between deep-groove ball bearing (1l) and parking lock gear.

10

Remove rear engine mount holder  (1h).

Transmission 722.9 (except 722.96) in model 204, 207, 216, 221
Transmission 722.9 (except 722.96/97) in model 205, 212, 217, 218, 222
Transmission 722.9 in model 171, 172, 203, 209, 211, 215, 219, 220, 230, 231, 463
Transmission 724.2

11

Attach support plate (P1) and valve lifter (H) for prying off transmission housing (1).

Transmission 722.9 (except 722.96) in model 204, 207, 216, 221
Transmission 722.9 (except 722.96/97) in model 205, 212, 217, 218, 222
Transmission 722.9 in model 171, 172, 203, 209, 211, 215, 219, 220, 230, 231, 463
Transmission 724.2

 Support plate

*722589003100

 Valve lifter

*442589003100

12

Unscrew screws (11w, 12w).


Position transmission so that it is vertical with torque converter housing (1w) or electric machine housing facing downward.
Otherwise, the transmission housing (1) will fall down after removing the last screw (11w, 12w).

13.1

Remove transmission housing (1) from torque converter housing (1w) or electric machine housing using valve lifter (H).

Transmission 722.9 (except 722.96) in model 204, 207, 216, 221
Transmission 722.9 (except 722.96/97) in model 205, 212, 217, 218, 222
Transmission 722.9 in model 171, 172, 203, 209, 211, 215, 219, 220, 230, 231, 463
Transmission 724.2

 Valve lifter

*442589003100

13.2

Remove transmission housing (1) from torque converter housing (1w).

Transmission 722.9 in model 164, 166, 251, 292
Transmission 722.96 in model 204, 207, 216, 221
Transmission 722.96/97 in model 205, 212, 217, 218, 222

14

Remove support plate (P1) and valve lifter (H).

Transmission 722.9 (except 722.96) in model 204, 207, 216, 221, 463
Transmission 722.9 (except 722.96/97) in model 205, 212, 217, 218, 222
Transmission 722.9 in model 171, 172, 203, 209, 211, 215, 219, 220, 230, 231
Transmission 724.2

 Support plate

*722589003100

 Valve lifter

*442589003100

Install

15

Align disks in transmission housing  (1), and position transmission housing (1) on torque converter housing (1w) or electric machine housing.


Place the transmission housing (1) carefully.
Otherwise, the disks of clutch pack BR (5) and multidisk brake B2 (6) may break off.

16

Slide output flange (20) or connecting flange (22) onto power output shaft (24).

17

Place transmission housing (1) on torque converter housing (1w) or electric machine housing.


Never tighten the transmission housing (1) against the torque converter housing (1w) or electric machine housing using the screws (11w, 12w).
Otherwise the disks of the clutch pack BR (5) and multidisk brake B2 (6) may break off.

 By abruptly turning the output flange  (20) or connecting flange  (22) of the output shaft  (24) while simultaneously lifting the transmission housing  (1), the transmission housing  (1) gradually slips onto the seal (1d) of the torque converter housing  (1w) or electric machine housing.

18

Detach output flange (20) or connecting flange (22) from power output shaft (24).



Check

19

Check that there is no gap between transmission housing (1) and torque converter housing (1w) or electric machine housing.

 The transmission housing (1) must lie completely flush (without gaps) against the seal (1d) on the torque converter housing  (1w) or electric machine housing (arrow).

20

Screw in screws (11w, 12w).

 Install new screws (11w, 12w).

 Transmission 722.9 in model 164, 166, 171, 172, 203, 204, 205, 207, 209, 211, 212, 215, 216, 217, 218, 219, 220, 221, 222, 230, 231, 251, 292Bolt, transmission housing to torque converter housing

*BA27.40-P-1015-01A

 Model 463 with transmission 722.9Bolt, transmission housing to converter housing

*BA27.40-P-1009-01E

 Transmission 724.2Bolt, transmission housing to clutch housing

*BA27.10-P-1024-04G

21

Insert shim between deep-groove ball bearing (1l) and parking lock gear.

Transmission 722.9 (except 722.96/97), 724.2

AR27.50-P-0600-06A

Transmission 722.96 in model 204, 205, 212, 216, 217, 218, 221, 222
Transmission 722.97 in model 205, 212, 217, 218, 222

AR27.50-P-0600-06SYZ

 For axial play measurement, determine shim thickness of shim using a digital vernier caliper.

End play between park pawl gear and grooved ball bearing

*BE27.50-P-1004-01A

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

 Parallel rest

*126589043100

22

Install deep-groove ball bearing (1l).

Transmission 722.9, 724.2

AR27.50-P-0600-05A

 Check the play and insert retaining ring.

23

Install radial shaft sealing ring (1r).


Do not damage seat of radial shaft sealing ring  (1r).
Otherwise leaks may occur.

 Drive new radial shaft sealing ring  (1r) into rear cap using  drift, until  drift contacts rear cap.

 Drift

*140589121500

24

Attach rear engine mount holder  (1h).

Transmission 722.9 (except 722.96) in model 204, 207, 216, 221
Transmission 722.9 (except 722.96/97) in model 205, 212, 217, 218, 222
Transmission 722.9 in model 171, 172, 203, 209, 211, 215, 219, 220, 230, 231, 463
Transmission 724.2

 Replace bolts.

 Transmission 722.9 in model 463Bolt, bracket for rear engine mount to transmission

*BA27.40-P-1012-01E

 Transmission 722.9 (except 722.96) in model 204, 207, 216, 221
Transmission 722.9 (except 722.96/97) in model 205, 212, 217, 218, 222
Transmission 722.9 in model 171, 172, 203, 209, 211, 215, 219, 220, 230, 231Bolt, bracket for rear engine mount to transmission

*BA27.40-P-1018-01A

 Transmission 724.2Screw/bolt, rear bracket to transmission

*BA27.10-P-1007-04G

25

Install connecting flange (22) and tighten new collar nut (23).

Transmission 722.9 in model 164, 166, 251, 292

 Collar nut, output flange to output shaft

*BA27.50-P-1001-01A

26

Place intermediate housing (21) onto transmission housing (1) and screw in screws (19).

Transmission 722.9 in model 164, 166, 251, 292

 Ensure that the dowel pins in the intermediate housing (21) are seated correctly.

 Replace screws  (19).

 Bolt, intermediate housing to transmission housing

*BA27.40-P-1020-01A

27.1

Install output flange (20) and tighten new collar nut (23).

Transmission 722.9 (except 722.96) in model 204, 207, 216, 221
Transmission 722.9 (except 722.96/97) in model 205, 212, 217, 218, 222
Transmission 722.9 in model 166.058, 171, 172, 203, 209, 211, 215, 219, 220, 230, 231
Transmission 722.9 in model 251.021/026/054/056/126/154/156
Transmission 722.9 in model 463
Transmission 724.2

AR27.50-P-0620-02W

 Transmission 722.9Collar nut, output flange to output shaft

*BA27.50-P-1001-01A

 Transmission 724.2Collar nut, output flange to output shaft

*BA27.10-P-1014-04G

 Socket wrench bit

*126589020900

 Pin wrench

*129589010700

27.2

Attach transfer case.

Transmission 722.9 in model 164, 166 (except 166.058), 251 (except 251.021/026/054/056/126/154/156), 292
Transmission 722.96 in model 204, 216, 221
Transmission 722.96 in model 207.3 with engine 276
Transmission 722.96/97 in model 205, 212, 217, 218, 222

Transmission 722.9 in model 164

AR28.10-P-0100GZ

Transmission 722.9 in model 251.020/022/065/072/075/077/122/157/165/172/175/177

AR28.10-P-0100RT

Transmission 722.9 in model 166 (except 166.058), 292

AR28.10-P-0100GQ

Transmission 722.96/97 in model 205

AR28.10-P-1004LWY

Transmission 722.96/97 in model 217, 222

AR28.10-P-1004LFX

Transmission 722.96 in model 204 with engine 272
Transmission 722.96 in model 204 with engine 642
Transmission 722.96 in model 204 with engine 651
Transmission 722.96 in model 204, 207.38 with engine 276
Transmission 722.96 in model 204.9 with engine 274

AR28.10-P-1004CWX

Transmission 722.96/97 in model 212, 218

AR28.10-P-1004EW

Transmission 722.96 in model 216, 221

AR28.10-P-1004SYZ

27.3

Attach adapter housing.

Transmission 722.9 in model 166.058, 251.021/026/054/056/126/154/156

Transmission 722.9 in model 251.026/054/056/126/154/156

AR27.30-P-0800RT

Transmission 722.9 in model 166.058

AR27.30-P-0800GQ

28

Install electrohydraulic controller unit  (4).

Transmission 722.9

AR27.19-P-0200W

Transmission 724.2

AR27.19-P-0200EH

29

Install electric machine.

Transmission 724.2

AR08.10-P-0012EH

30

Detach transmission from assembly stand.



000 588 00 31 00 Assembly stand for cars

Transmission 724.2

WS01.00-N-3028B

 Transmission 722.9
Mounting plate

*140589346300

 Transmission 722.9
Assembly stand

*116589065900

 Transmission 724.2
Assembly device

*724589044000

 Transmission 724.2
Lifting device

*724589026300

Check values for gear set

Number

Designation

Transmission 722.9

Transmission 724.2

BE27.50-P-1004-01A

End play between park pawl gear and grooved ball bearing

mm

0,20...0,40

0,20...0,40

 Automatic transmission complete

Number

Designation

Transmission 724.2

BA27.10-P-1007-04G

Screw/bolt, rear bracket to transmission

Stage 1

Nm

10

Stage 2

°

90

 Automatic transmission complete

Number

Designation

Transmission 724.2

BA27.10-P-1014-04G

Collar nut, output flange to output shaft

Nm

200

 Automatic transmission complete

Number

Designation

Transmission 724.2

BA27.10-P-1024-04G

Bolt, transmission housing to clutch housing

Stage 1

Nm

10

Stage 2

°

90

 Housing

Number

Designation

Transmission 722.9 in model 463

BA27.40-P-1009-01E

Bolt, transmission housing to converter housing

Stage 1

Nm

10

Stage 2

°

90

 Housing

Number

Designation

Transmission 722.9 in model 463

BA27.40-P-1012-01E

Bolt, bracket for rear engine mount to transmission

Stage 1

Nm

10

Stage 2

°

90

 Housing

Number

Designation

Transmission 722.9

BA27.40-P-1015-01A

Bolt, transmission housing to torque converter housing

Stage 1

Nm

10

Stage 2

°

90

 Housing

Number

Designation

Transmission 722.9

BA27.40-P-1018-01A

Bolt, bracket for rear engine mount to transmission

Stage 1

Nm

10

Stage 2

°

90

 Housing

Number

Designation

Transmission 722.9

BA27.40-P-1020-01A

Bolt, intermediate housing to transmission housing

Stage 1

Nm

10

Stage 2

°

90

 Gear assembly

Number

Designation

Transmission 722.55/6/9

BA27.50-P-1001-01A

Collar nut, output flange to output shaft

Nm

200

Repair materials

Number

Designation

Order number

BR00.45-Z-1038-04A

Loctite 7200

Henkel AG & Co. KGaA
http://www.loctite.de

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09