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Dismantling and assembling transmission (section 4) - AR27.50-P-0780A: Notes

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TRANSMISSION 722.5 

Fig 1: Identifying Transmission Components (Section 4)
G04679464Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
DISASSEMBLING Disassembling     
NOTES The gear set may fall out    
1 Disassembling transmission (section 1)   AR27.50-P-0600A 
2 Disassembling transmission (section 2)   AR27.50-P-0620A 
3 Disassembling transmission (section 3)   AR27.50-P-0720A 
4 Pull bearing B1 (31) out of housing by unscrewing Allen bolt (33) or transmission overload protection switch (S65) NOTES The gear set may fall out.
IMPORTANT Switch (S65) only installed in model 463 with M104 and M117		  
    TORQUE SPECIFICATION *BA27.40-P-1001-01A 
5 Remove brake band piston B1 (37) SPECIAL TOOL Assembly device AR27.50-P-0780-01A 
6 Pull gear set (87), clutch K1 (83), brake band B1 (30) and multi-disc assembly for multi-disc brake LB3 (133) together out of housing    
    IMPORTANT According to findings: ↓ AR27.50-P-0780-02A 
    Disassembling and assembling gear set AR27.50-P-0840A 
    Disassembling and assembling clutch K1 AR27.51-P-0800A 
7 Remove damper spring (134) from housing    
8 Remove brake band piston B2 (15) by pressing in brake band piston cover B2 (17) and removing locking ring (23)    
9 Remove plastic guide ring (88a) and radial liptype sealing ring B2 (88) from housing    
10 Remove clutch K2 (100) from housing IMPORTANT According to findings: ↓  
    Disassembling and assembling clutch K2 AR27.51-P-0820A 
11 Remove brake band B2   AR27.50-P-0780-03A 
12 Remove support washer (113) from support flange (79)    
13 Remove support flange (79) from housing by unscrewing Allen bolts (80)    
ASSEMBLING Assembly     
14 Install support flange (79) with O-rings (197) and Teflon rings (115) in transmission housing IMPORTANTInstallation  : Before installing the support flange (79), ensure that the lubrication constrictor is inserted in the support flange (79).  
    Arrangement of lubrication constrictor, oil duct K2, in support flange
IMPORTANT To install the support flange (79), use two bolts approx. 80 mm long for centering
Press Teflon rings (115) into the grooves so that their splits are in alignment		 AR27.50-P-0780-12A 
    TORQUE SPECIFICATION *BA27.50-P-1003-01A 
15 Push support washer (113) onto support flange (79) IMPORTANT Note installed position  
16 Insert bearing B2 (29) with pressure pin (28) in transmission housing IMPORTANT Large diameter of pressure pin (28) points towards brake band B2 (27)  
17 Insert plastic guide ring (88a) and radial lip-type sealing ring (88) in housing IMPORTANT When installing, the sealing lip must point towards the brake band piston cover (17)  
REFER TO SHOP-MADE TOOLS Mandrel for radial lip-type sealing ring of brake band piston B2 722.5 WF58.50-P-2750-01A
18 Install brake band B2 (27)   AR27.50-P-0780-04A 
19 Install gear set (87) with clutch K2 (100)   AR27.50-P-0780-05A 
    SPECIAL TOOL Assembly device Figure
20 Install brake band piston B2 (15) by pressing down brake band piston cover B2 (17) and inserting locking ring (23)    
21 Install damper spring (134) IMPORTANT The bulge in the damper spring must face the drive shaft
The damper spring must also engage in the groove in the transmission housing		  
22 Install and measure multi-disc brake LB3   AR27.50-P-0780-06A 
    SPECIAL TOOL Parallel support Figure
23 Push clutch K1 (83) onto gear set (87)    
24 Install brake band B1 (30)   AR27.50-P-0780-07A 
25.1 Measure play of brake band B1 (30) IMPORTANT Up to transmission no. 3746851 AR27.50-P-0780-08A 
    SPECIAL TOOL Assembly device Figure
    SPECIAL TOOL Micrometer gauge Figure
25.2 Disassembling, assembling and basic setting of brake band piston B1 IMPORTANT As of transmission no. 3746852 AR27.50-P-0780-10A 
REFER TO COMPONENT MODIFICATIONS Self-adjusting brake band piston   BT27.50-P-0002-01A 
26 Measure play of brake band B2 (27)   AR27.50-P-0780-09A 
27 Assembling transmission (section 3)   AR27.50-P-0720A 
28 Assembling transmission (section 2)   AR27.50-P-0620A 
29 Assembling transmission (section 1)   AR27.50-P-0600A 
TEST VALUES OF BRAKE BAND/MULTI-DISC BRAKE

Number Designation Transmission 722.5
BE27.50-P-1002-02A Play in multi-disc brake B3 mm 1.5 - 2.0
BE27.50-P-1003-02A Play in brake band B1 mm 1.8 - 2.4
BE27.50-P-1004-02A Play in brake band B2 mm 5.5 - 6.0
TORQUE SPECIFICATION HOUSING

Number Designation Transmission 722.5
BA27.40-P-1001-01A Transmission overload protection switch to transmission housing Nm 70
TORQUE SPECIFICATION CROWN WHEEL/PINION

Number Designation Transmissions 722.3/4/5 Transmission 722.6
BA27.50-P-1003-01A Bolt, support flange K2 to transmission housing Nm 11 -
Fig 2: Identifying Assembly Device (201 589 03 59 00)
G04679465Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Parallel Support (126 589 04 31 00)
G04679466Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Identifying Micrometer Gauge (126 589 06 21 00)
G04679467Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Identifying Assembly Device (126 589 00 35 00)
G04679468Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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