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Dismantling and assembling transmission - RA2703722B640X(27-640)

WARNING: This page does not describe the selected car, but rather 42 other vehicles, including the 1999 Mercedes-Benz S600, 1999 Mercedes-Benz S500, 1999 Mercedes-Benz S420, 1999 Mercedes-Benz S320, and 1999 Mercedes-Benz CL600. However, it is still accessible from the selected car via links, so may be relevant.

Operation number of the operation texts and work units or standard texts and flat rates:

27-4010

Dismantling 

  1. Remove control pressure cable. Release locking device using a screwdriver (arrow) and detach control pressure cable.
    Fig 1: Locating Control Pressure Cable
    G04684462Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  2. Bolt mounting frame to assembly jig. Position transmission in the mounting frame and secure in place with the bolt (arrow).
    Fig 2: Locating Transmission Mounting Frame Bolt
    G04684463Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  3. Unscrew bolts with washers (4) and remove oil pan (3).

    Installation note 

    Tightening torque 8 Nm.

    Fig 3: Identifying Bolts With Washers
    G04684464Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  4. Unscrew cross-head bolts (6) and remove oil filter (5).

    Installation note 

    Tightening torque 4 Nm.

    Fig 4: Identifying Cross-Head Bolts And Oil Filter
    G04684465Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  5. Unscrew bolts (7/7a) and remove shift valve body (A).

    Installation note 

    Tightening torque 8 Nm.

    Note different lengths of bolts.

    Fig 5: Identifying Shift Valve Body Bolt
    G04684466Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  6. Unscrew hexagon bolts (140). Remove bracket (141) with leaf spring (142).

    Installation note 

    Tightening torque 8 Nm.

  7. Unscrew bolts with washers and lift off lower cover (13) with intermediate plate (14) and oil pipe (9). Dismantle lower cover (27-435).

    Installation note 

    Tightening torque 8 Nm.

    Fig 6: Identifying Hexagon Bolts, Bracket, With Leaf Spring
    G04684467Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  8. Remove one-way valve (49), brake band guide B2 (101), locating pin (135), temperature throttle (117) and oil deflector (119). Check that filler element (128) is correctly seated.
    NOTE: As of 08/90, the filler element (128) is no longer featured in several models of transmission.
    Fig 7: Identifying Valve, Brake Band Guide, Locating Pin, Temperature Throttle And Oil Deflector
    G04684468Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  9. Push in brake band plunger cover B2 (17) and remove circlip (23).
  10. Remove brake band plunger cover.
    Fig 8: Identifying Brake Band Plunger Cover And Circlip
    G04684469Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  11. Pull out brake band plunger B2 (15) with thrust pin (26) clipped in.

    Installation note 

    Adjust clearance "L" to 5.5 - 5.7 mm with thrust pin (26) (item 127).

    Fig 9: Identifying Brake Band Plunger B2 With Thrust Pin
    G04684470Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  12. Apply assembly device, bolt onto transmission housing and clamp.
  13. Remove circlip (41).
    Fig 10: Identifying Circlip
    G04684471Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  14. Release assembly device (026) and take off brake band plunger B1 (37) with thrust pin, cover (40) and return springs (35, 36).
  15. Unscrew assembly device (026).

    Installation note 

    Adjust clearance "L" to 1.8 - 2.0 mm as described in items 118 to 124.

    Fig 11: Identifying Assembly Device, Brake Band Plunger B1 With Thrust Pin
    G04684472Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  16. Pull out brake band guide B1 (34).
    Fig 12: Identifying Brake Band Guide B1
    G04684473Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  17. Unscrew screw plug (33) for thrust element B1 or pressure switch for transmission overload protection (33b).

    Installation note 

    Tightening torque 70 Nm. Replace O-Rings.

  18. Take out thrust element B1 (31)
    Fig 13: Identifying Screw Plug, Thrust Element B1 And Pressure Switch
    G04684474Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  19. Unscrew hexagon bolt (51) and pull off range selector lever (52).

    Installation note 

    Tightening torque 8 Nm.

    Fig 14: Identifying Hexagon Bolt And Range Selector Lever
    G04684475Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  20. Unscrew hexagon bolts (55) and remove starter lockout switch (53).

    Installation note 

    Tightening torque 8 Nm.

    Fig 15: Identifying Hexagon Bolts And Starter Lockout Switch
    G04684476Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  21. Remove vacuum unit (60) after unscrewing hexagon socket bolts (58) with retaining plate (57).

    Installation note 

    Tightening torque 8 Nm.

  22. Remove heat expansion pin (59a) and modulating pressure regulator valve (59).
    Fig 16: Identifying Vacuum Unit, Hexagon Socket Bolts With Retaining Plate
    G04684477Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  23. Unscrew kickdown solenoid valve (61).

    Installation note 

    Tightening torque 20 Nm.

  24. Engage parking lock. Unscrew twelve-point collared nut (62) and pull off propeller flange or internal gear (64a).

    Socket wrench 126 589 02 09 00.

    Installation note 

    Tightening torque 120 Nm.

    Fig 17: Identifying Kickdown Solenoid Valve And Twelve-Point Collared Nut
    G04684478Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  25. Remove washer (65).
  26. Unscrew hexagon bolts (71).
  27. Loosen rear cover (70) by tapping gently with a plastic mallet and remove.
  28. Dismantle rear cover (27-450).
    Fig 18: Identifying Rear Cover, Hexagon Bolts And Washer
    G04684479Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  29. In vehicles with electronic speedometer, remove parking lock gear (73) with rotor, parking lock pawl (74) and expanding spring (75).
    Fig 19: Identifying Electronic Speedometer Lock Gear, Parking Lock Pawl And Expanding Spring
    G04684480Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  30. In vehicles with mechanical speedometer, remove oil pipe (102), parking lock gear (73) with helical gear, parking lock pawl (74) and expansion spring (75).
    Fig 20: Identifying Oil Pipe, Parking Lock Gear With Helical Gear, Parking Lock Pawl And Expansion Spring
    G04684481Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  31. Pull off plastic guide (80) upwards and then remove roller (81).
    Fig 21: Identifying Plastic Guide And Roller
    G04684482Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  32. Unscrew hexagon socket bolt (82a), pull out shaft (76) and remove notched plate (82) with spring linkage.
    Fig 22: Identifying Hexagon Socket Bolt And Shaft
    G04684483Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  33. Unscrew hexagon socket bolt (84a) and remove with oil pipe (84)

    Installation note 

    Tightening torque 8 Nm.

    NOTE: As from 04/89 the oil pipe (84) for governor lubrication is not used any more.
    Fig 23: Identifying Hexagon Socket Bolt And Oil Pipe
    G04684484Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  34. Unscrew nut (44) from axial retainer for the centrifugal governor.

    Installation note 

    Tightening torque 6 Nm.

  35. Unscrew hexagon socket bolts (45) and remove secondary pump (20).

    Installation note 

    Tightening torque 8 Nm.

    Fig 24: Identifying Secondary Pump, Hexagon Socket Bolts And Nut
    G04684485Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  36. Remove O-ring (22) and intermediate plate (21) of secondary pump.
    Fig 25: Identifying O-Ring And Intermediate Plate Of Secondary Pump
    G04684486Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  37. Press in cover (46) for centrifugal governor and remove circlip (47).
  38. Pull out cover (46).
    Fig 26: Identifying Cover And Circlip
    G04684487Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  39. Swivel axial retainer (43) back and then pull out centrifugal governor (50). Take out axial retainer.
  40. Pull off shim and helical gear (78).
    Fig 27: Locating Helical Gear
    G04684488Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  41. Remove snap ring (116) from drive shaft (86). Pliers 000 589 52 37 00
    Fig 28: Identifying Snap Ring And Drive Shaft
    G04684489Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  42. Unscrew bolts with washers from front cover.

    Installation note

    Tightening torque 13 Nm.

  43. Screw two bolts into threaded bores (arrows) and then use these to pull out the front cover (10).
    Fig 29: Locating Front Cover Bolts
    G04684490Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  44. Take hold of gear set on drive shaft (87) and carefully pull out forwards.
  45. Pull clutch K1 (83) with brake band B1 (30) off gear set.
  46. Remove multiple-discs of LB3 (arrow).
    Fig 30: Identifying Clutch K1, Brake Band B1 And Drive Shaft
    G04684491Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  47. Take out damping spring (134).
    Fig 31: Identifying Damping Spring
    G04684492Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  48. Remove thrust pin.
  49. Take out clutch K2 (100).
    Fig 32: Identifying Clutch K2
    G04684493Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  50. Move brake band B2 (27) to a diagonal position, compress and remove.
    NOTE: Lateral cracks in the lining of brake band B2 are not important.
  51. Pull out thrust element B2 (29).
    Fig 33: Identifying Thrust Element And Brake Band
    G04684494Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  52. Unscrew hexagon bolts (114). Screw two bolts, approx. 80 mm long, into two opposite holes. Slacken support flange (79) from housing by tapping both bolts with a hammer.

    Installation note 

    Tightening torque 11 Nm.

  53. Remove any sealing rings, test connection plugs etc. remaining in the housing.
  54. Remove housing from assembly device.
    Fig 34: Identifying Hexagon Bolts And Support Flange
    G04684495Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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