Disassemble, assemble and seal

AR28.10-P-1004EW

Disassemble, assemble and seal

06.03.2020

Model

212, 218 with transmission 722.96/97

Modification notes

15.05.2014

Bolt, ring gear to two-part output shaft

BA28.10-P-1003-01F

21.06.2017

Bolt, ring gear to two-part output shaft

BA28.10-P-1003-01F

1

Collar nut

2

Output flange

3

Radial shaft sealing ring

4

Intermediate housing

5

Automatic transmission

6

Retaining ring

7

Deep-groove ball bearing

8

Bolts

9

Rear cover

10

Retaining ring

11

Output shaft

12

Oil filler plug

13

Connecting bolt

14

Ring gear with intermediate shaft

15

Needle bearing

23

Drain screw

24

Transfer case

4

Intermediate housing

5

Automatic transmission

14

Ring gear with intermediate shaft

16

Planet carrier

17

Bolts

18

Drive pinion of transfer case

19

Differential side gear of front axle propeller shaft

20

Radial shaft sealing ring

21

Shim

22

Pilot bushing

5

Automatic transmission

20

Radial shaft sealing ring

Topical note

General information on repair work on transmission

AH27.00-S-1000-01PS

 

Remove/install

1

Move DIRECT SELECT gear selector switch to "N" position

2

Detach ground line from battery

AR54.10-P-0003EW

Topical note

Notes on battery

AH54.10-P-0001-01A

3

Secure vehicle on vehicle lift

AR00.60-P-0100EWS

4.1

Remove right catalytic converter

Model 212 with engine 272 with transmission 722.96
Model 212 with engine 273 with transmission 722.96

AR49.10-P-7100EW

4.2

Remove diesel particulate filter

Model 212 with engine 642 with transmission 722.96
Model 212 with engine 651 with transmission 722.96
Model 218 with engine 642 with transmission 722.96

Model 212 with engine 642 with transmission 722.96
Model 212 with engine 651 with transmission 722.96

AR49.10-P-7100EWI

Model 218 with engine 642 with transmission 722.96

AR14.40-P-1000OGE

4.3

Remove rear part of exhaust system

Model 212 with engine 157 with transmission 722.96/97
Model 212, 218 with engine 276 with transmission 722.96
Model 212, 218 with engine 278 with transmission 722.96
Model 218 with engine 157 with transmission 722.97

AR49.10-P-7100EL

5

Support automatic transmission (5) 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

6

Remove rear engine cross member

MODEL 212, 218

AR22.10-P-1180CW

Topical note

Notes on bolted connections with self tapping screws

AH00.00-P-0007-01SF

7

Detach flexible coupling from transfer case (24) and propeller shaft

AR41.10-P-0050EW

8

Lower the automatic transmission (5)

9

Remove front axle transmission propeller shaft

Model 212, 218 with transmission 722.97
Model 212.08/09/28/29, 218.39/99 with transmission 722.96
When replacing the radial shaft sealing ring (20) or during repair work on the automatic transmission (5)

AR41.10-P-0070EWX

10

Remove heat shield from underfloor in area of transfer case (24)

11

Detach stiffening bridge from underfloor

 Bolt, front reinforcement brace to frame floor assembly

*BA61.10-P-1002-01H

 Bolt, rear reinforcement brace to frame floor assembly

*BA61.10-P-1003-01H

12

Drain oil out of transfer case (24); to do so, remove drain screw (23) from intermediate housing (4)

 Installation: Replace seal.

 Model 212, 218 with transmission 722.96Drain screw to intermediate housing

*BA28.10-P-1006-01E

 Model 212, 218 with transmission 722.97Drain screw to intermediate housing

*BA28.10-P-1006-01F

13

Remove intelligent servo module (ISM)

Only to remove the ring gear (14).

AR27.19-P-0550EW

 

Disassemble/assemble

14

Detach collar nut (1) from output flange (2)

 Installation: Replace collar nut (1) and secure after tightening.

 Model 212, 218 with transmission 722.96Collar nut, output flange to output shaft

*BA28.10-P-1004-01E

 Model 212, 218 with transmission 722.97Collar nut, output flange to output shaft

*BA28.10-P-1004-01F

 Pin wrench

*129589010700

 Socket wrench bit

*126589020900

 Adapter

*100589025900

15

Detach output flange (2) from output shaft (11)

 Check output flange (2) for wear and damage and replace if necessary.

 Use puller if output flange (2) is seized.

 Puller

*124589043300

16

Remove radial shaft sealing ring (3) from rear cover (9)

In the event of leakage or when replacing the grooved ball bearing (7).


Do not damage seat of radial shaft sealing ring (3).
Leaks may otherwise occur.

 Installation: Use drift to drive in new radial shaft sealing ring (3) until it abuts with the rear cover (9).

 Drift

*140589121500

Check seat of radial shaft sealing ring (3) for wear and damage; in case of complaints,



replace rear cover (9).

17

Remove rear cover (9); to do this, unscrew bolts (8) and remove rear cover (9)

 Installation:
The sealing surfaces on intermediate housing (4) and rear cover (9) must be free of oil and grease.
This prevents leaks occurring.

 Model 212, 218 with transmission 722.96Bolt, transmission cover to intermediate housing

*BA28.10-P-1002-01E

 Model 212, 218 with transmission 722.97Bolt, transmission cover to intermediate housing

*BA28.10-P-1002-01F

Loctite 7200

*BR00.45-Z-1038-04A

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

18

Remove grooved ball bearing (7); to do this, remove retaining ring (6) from rear cover (9) and press out grooved ball bearing (7)

 The grooved ball bearing (7) only has to be replaced in the event of complaints or damage.

19

Remove retaining ring (10) and remove output shaft (11)

 Installation: Check retaining ring (10) for correct seat in planet carrier (16).

Check retaining ring (10) for deformation and damage, if necessary:



Replace retaining ring (10).

20

Using the assembly tool move the automatic transmission (5) into position "P" at the range selector shaft

When removing the ring gear (14)

 Assembly tool

*722589030900

21

Detach needle roller bearing (15) from ring gear (14)

Check needle roller bearing (15) for wear and damage; if necessary,



replace needle roller bearing (15).

22

Remove connecting bolt (13)

 Installation: Connecting bolt (13) must always be replaced.

 Model 212, 218 with transmission 722.96Bolt, ring gear to two-part output shaft

*BA28.10-P-1003-01E

 Model 212, 218 with transmission 722.97Bolt, ring gear to two-part output shaft

*BA28.10-P-1003-01F

23

Remove ring gear (14) using pulling device

AR28.10-P-1001-02SYZ

 Pay attention to correct seat of pulling device on ring gear (14).

 Installation: Press on ring gear (14) by hand and pull in using new connecting bolt (13).

 Extraction tool

*722589013300

24

Remove planet carrier (16)

25

Remove bolts (17) and remove intermediate housing (4)

 Installation:
Sealing surfaces on intermediate housing (4) and automatic transmission (5) must be free of oil and grease.
This prevents leaks occurring.

 Installation: Assembly sleeve must be removed from differential side gear (19) before attaching the intermediate housing (4).

 Model 212, 218 with transmission 722.96Bolt, intermediate housing to transmission housing

*BA28.10-P-1001-01E

 Model 212, 218 with transmission 722.97Bolt, intermediate housing to transmission housing

*BA28.10-P-1001-01F

Loctite 7200

*BR00.45-Z-1038-04A

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

26

Remove differential side gear (19)

 Installation:
Assembly sleeve must be used when installing differential side gear (19).
This prevents the radial shaft sealing ring (20) of the differential side gear (19) from being damaged in the transmission housing.

 Installation: Pay attention to the correct seat of assembly sleeve on differential side gear (19).

 Assembly sleeve

*722589061400

27

Remove drive pinion (18)

28

Remove radial shaft sealing ring (20) of differential side gear (19) using a suitable tool


Do not support tool for prying off radial shaft sealing ring (20) from the automatic transmission (5) without using a rag.
The sealing surface on the automatic transmission (5) could otherwise be damaged (see picture 3).

 Installation: Replace the radial shaft sealing ring (20) and make sure that it is installed in the correct position (see enlarged detail in picture 3).

 Installation: Drive radial shaft sealing ring (20) into transmission housing using drift. Make sure that the radial shaft sealing ring (20) is seated correctly in the automatic transmission (5).

 Drift

*722589141500

29

Remove pilot bushing (22) and shim (21) from output shaft (11)

The basic dimension must be determined before repair work on the automatic transmission (5):



Measure end play between park pawl gear and grooved ball bearing

AR27.50-P-0600-06SYZ

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

30

Assembly in reverse order



Clean

31

Clean all parts of the transfer case (24) thoroughly

Assembly cleaner

*BR00.45-Z-1028-04A

32

Install in the reverse order

33

Prefill transfer case (24) with a prefill quantity of 0.7 l transmission oil and fill automatic transmission (5) with transmission oil

The transfer case (24) is connected to the oil circuit of the automatic transmission (5). The oil level can therefore only be checked and corrected via the automatic transmission (5):



Fill automatic transmission with transmission oil

AR27.00-P-0270SYZ

 Model 212, 218 with transmission 722.96Filling screw to intermediate housing

*BA28.10-P-1005-01E

 Model 212, 218 with transmission 722.97Filling screw to intermediate housing

*BA28.10-P-1005-01F

 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

34

Test run engine and check the automatic transmission (5) and transfer case (24) for leak tightness and function

Check values for gear set

Number

Designation

Transmission 722.9

BE27.50-P-1004-01A

End play between park pawl gear and grooved ball bearing

mm

0,20...0,40

 Complete transfer case

Number

Designation

Model 204, 205, 207, 212, 216, 217, 218, 221, 222 with transmission 722.96

BA28.10-P-1001-01E

Bolt, intermediate housing to transmission housing

Nm

20

 Complete transfer case

Number

Designation

Model 205, 212, 217, 218, 222 with transmission 722.97

BA28.10-P-1001-01F

Bolt, intermediate housing to transmission housing

Nm

20

 Complete transfer case

Number

Designation

Model 204, 205, 207, 212, 216, 217, 218, 221, 222 with transmission 722.96

BA28.10-P-1002-01E

Bolt, transmission cover to intermediate housing

Nm

8

 Complete transfer case

Number

Designation

Model 205, 212, 217, 218, 222 with transmission 722.97

BA28.10-P-1002-01F

Bolt, transmission cover to intermediate housing

Nm

8

 Complete transfer case

Number

Designation

Model 204, 205, 207, 212, 216, 217, 218, 221, 222 with transmission 722.96

BA28.10-P-1003-01E

Bolt, ring gear to two-part output shaft

Stage 1

Nm

30

Stage 2

°

180

 Complete transfer case

Number

Designation

Model 205, 212, 217, 218, 222 with transmission 722.97

BA28.10-P-1003-01F

Bolt, ring gear to two-part output shaft

Stage 1

Nm

30

Stage 2

Loosen

°

360

Stage 3

Nm

5

 Complete transfer case

Number

Designation

Model 204, 205, 207, 212, 216, 217, 218, 221, 222 with transmission 722.96

BA28.10-P-1004-01E

Collar nut, output flange to output shaft

Nm

200

 Complete transfer case

Number

Designation

Model 205, 212, 217, 218, 222 with transmission 722.97

BA28.10-P-1004-01F

Collar nut, output flange to output shaft

Nm

200

 Complete transfer case

Number

Designation

Model 204, 205, 207, 212, 216, 217, 218, 221, 222 with transmission 722.96

BA28.10-P-1005-01E

Filling screw to intermediate housing

Nm

20

 Complete transfer case

Number

Designation

Model 205, 212, 217, 218, 222 with transmission 722.97

BA28.10-P-1005-01F

Filling screw to intermediate housing

Nm

20

 Complete transfer case

Number

Designation

Model 204, 205, 207, 212, 216, 217, 218, 221, 222 with transmission 722.96

BA28.10-P-1006-01E

Drain screw to intermediate housing

Nm

30

 Complete transfer case

Number

Designation

Model 205, 212, 217, 218, 222 with transmission 722.97

BA28.10-P-1006-01F

Drain screw to intermediate housing

Nm

30

 Frame floor assembly

Number

Designation

Model 212

Model 218

BA61.10-P-1002-01H

Bolt, front reinforcement brace to frame floor assembly

Nm

30

30

 Frame floor assembly

Number

Designation

Model 212

Model 218

BA61.10-P-1003-01H

Bolt, rear reinforcement brace to frame floor assembly

Nm

24

24

Repair materials

Number

Designation

Order number

BR00.45-Z-1013-01A

Sealant, Loctite 5970, 50 ml

A 003 989 98 20 10

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01

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