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Dismantling and assembling transmission - RA2703722D640X(27-640)

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

27-4010

Dismantling brake band plunger 

Remove brake band plunger from plunger cover. Spread locking device (40a) in brake band plunger cover (40) using circlip pliers and remove pin (37c). Leave the locking device in the brake band plunger cover.

Remove snap ring (illustration 3, item 37b) in brake band plunger using a screwdriver; then remove disk spring.

Fig 1: Identifying Brake Band Plunger From Plunger Cover
G04684569Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Illustration 2

Assembling brake band plunger 

Insert pin (37c) in brake band plunger.

Note installed position  .

Push disk spring (37a) over pin until it contacts the brake band plunger; note installed  position. Insert snap ring (37b). Ensure that it is correctly seated.

Press assembled brake band plunger into plunger cover until it locks in position audibly. Do not  pull it apart by hand once it has locked.

Install assembled brake band plunger; it adjusts itself automatically.

Fig 2: Identifying Pin In Brake Band Plunger
G04684570Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Illustration 3

  1. 122 Insert pressure pin thrust bearing B2 (28) with larger diameter pointing towards brake band B2 (27).
    Fig 3: Identifying Pressure Pin Thrust Bearing With Larger Diameter Pointing Towards Brake Band
    G04684571Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  2. 123 Insert Teflon ring (25) into groove with grease.
    NOTE: Introduction of improved Teflon ring (molded T-ring) as of transmission no. 3 915 083
  3. 124 Insert pressure pin (26)
    NOTE: Pressure pins (26) are available in lengths of 47.2, 48.0, 48.8 and 49.6 mm for correcting the idle travel at brake band B2.
    Fig 4: Identifying Teflon Ring And Pressure Pins
    G04684572Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  4. 125 Introduce brake band plunger B2 (15) ensuring that pressure pin (26) engages in brake band.
    Fig 5: Identifying Brake Band Plunger And Pressure Pin
    G04684573Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Repair note for reconditioned transmission 

    Phased in as of 06/94 the bore for supporting plunger B2 is reworked after wear limit is reached. This necessitates a modified sealing ring with a larger diameter for plunger B2. The housing is identified by engraving "89 dia.".

    NOTE: Only the modified sealing rings may be installed when repairing reconditioned transmissions, the housings of which are identified with the diameter specifications (89).
    Fig 6: Identifying Transmissions Diameter Specifications
    G04684574Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  5. 126 Press in brake band plunger cover B2 (17) and insert circlip (23).
    Fig 7: Identifying Brake Band Plunger Cover And Insert Circlip
    G04684575Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  6. 127 Measure clearance "L" at brake band B2 and adjust.
  7. Press brake band B2 (27) by the support tab towards the brake band plunger (in direction of arrow) so that brake band plunger rests against brake band plunger cover. Measure distance "a" at brake band using caliper gauge.
    Fig 8: Identifying Distance "A" Brake Band
    G04684576Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Similarly, press brake band B2 (27) by the support tab towards the thrust element (in direction of arrow).

    Measure distance "b".

    The difference between measurements "a" and "b" is equal to the clearance "L".

    Adjust clearance "L" to 5.5 - 5.7 mm by replacing the thrust pin (26) at brake band plunger B2.

    Fig 9: Identifying Difference Between Measurements "A" And "B"
    G04684577Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  8. 128 Insert brake band guide B2, one-way valve (49), filler element (128), locating pin (135), temperature restrictor (117) and oil deflector (119) in transmission housing.
    Fig 10: Identifying Filler Element, Locating Pin, Temperature Restrictor And Oil Deflector
    G04684578Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  9. 129 Assemble lower cover (13) with intermediate plate (14) (27-430) .

    Attach lower cover with intermediate plate ensuring that the oil pipe (9) is inserted into the bore (arrow).

    Fig 11: Locating Oil Pipe Into Bore
    G04684579Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  10. 130 Center intermediate plate (14) with two bolts (7).
  11. 131 Insert bolts with washers (8) and tighten to 8 Nm.
  12. 132 Attach leaf spring (142) with bracket (141) and tighten bolt (140) to 8 Nm.
    NOTE: Ensure that the locating pin for the brackets (141) is correctly inserted.
    Fig 12: Identifying Center Intermediate Plate With Bolts
    G04684580Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  13. 133 Mount range selector lever (52) so that the driver (54) is located in the range selector lever.
  14. 134 Insert hexagon bolt (51) and tighten to 8 Nm.
  15. 135 Move range selector lever (52) to position "N", insert a 4 mm cotter pin (arrow) through the range selector lever into the locating bore of the shift housing and tighten hexagon bolts (55) to 8 Nm. Then remove cotter pin.
    Fig 13: Identifying Angle Selector Lever Position
    G04684581Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  16. 136 Attach shift valve housing (A), ensuring that the range selector lever (A1) engages in the driver on the notched plate (arrow).
    Fig 14: Locating Range Selector Lever
    G04684582Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  17. 137 Insert bolts with washers (7) and tighten to 8 Nm.

    IMPORTANT

    Note length of bolts. The three bolts marked with item no. 7a are only 50 mm, the remaining 12 bolts are 55 mm long.

    Fig 15: Identifying Bolts With Washers
    G04684583Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  18. 138 Check play "a" between locking plunger (122) and stop on spring linkage (82), and adjust if necessary.

    The play "a" is adjusted to 0.4 - 1.0 mm in position "N" by means of the plastic clip (118). The plastic clip is available in two thicknesses.

    Fig 16: Identifying Selector Lever Play Adjust
    G04684584Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  19. 139 Check O-ring on control pressure cable and renew if necessary, then attach control pressure cable onto connecting rod (110). Insert limiting rod (111) into bore (arrow) and insert control pressure cable.
  20. 140 Turn control pressure cable until it locks in place.
    Fig 17: Locating Control Pressure Cable Onto Connecting Rod
    G04684585Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  21. 141 Attach oil filter and tighten cross-head bolts to 4 Nm.
  22. 142 Attach oil pan (3) and tighten retaining bolts

    (4) to 8 Nm.

    Fig 18: Identifying Cross-Head Bolts
    G04684586Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  23. 143 Remove bolt (arrow) and lift transmission out of assembly unit.

    IMPORTANT

    After installation, check transmission for leaks and also check modulating pressure and adjust if necessary.

    Fig 19: Locating Transmission Bolts
    G04684587Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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