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Removing, installing, dismantling and assembling rear cover (transmission in situ) - RA27037220440X(27-440)

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

27-5585

Fig 1: Identifying Rear Cover (Transmission In Situ) Components
G04684309Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Exhaust system from plug connection, heat shield, rear engine mount and exhaust support Remove, install (items 4-7).
Oil from transmission (1) Drain, correct oil level after repairs (Maintenance, op. item 2710).
Cable for kickdown solenoid valve, pulse generator or speedometer shaft Remove, install (item 8).
Propeller shaft Unscrew at joint flange, slacken clamping nut and compress propeller shaft (item 9).
Clamping nut 30-40 Nm
Torque wrench 001 589 66 21 00
Open-end wrench 126 589 00 01 00
Twelve-point collared nut (62) Unscrew, screw on, 120 Nm. To do this, select parking lock (items 10, 11).
Wrench socket 126 589 02 09 00
Joint flange (64) or internally-geared wheel (64a) Pull off, remove washer (65) (item 12).
Rear cover (70) or adapter housing (70a) Remove, install; unscrew, screw on combined bolts and washers (71), 13 Nm (8.8) or 28 Nm (10.9). Check gasket (72 or 64b).
Radial seal ring (66) Press out using screwdriver, press in new sealing ring using suitable alignment tool (item 14).
Circlip (68) Remove, install; knock out single-row deep-groove ball bearing, knock in; check. Attach circlip without play (available in thicknesses 2.0 - 2.1 - 2.2) (item 15).
Small drive gear (129) Remove, install; remove circlip (131) and take out shaft (130) (item 16).
Radial sealing ring (132) Replace, knock in using shop-made drift (item 17).
Plastic bushing (69) With electronic speedometer: replace with O-ring in event of leaks, use shop-made tool for knocking in (item 18).

Special tools 

Fig 2: Identifying Special Tools (001 589 66 21 00)
G04684310Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Special Tools (126 589 00 01 00)
G04684311Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Identifying Special Tools (126 589 02 09 00)
G04684312Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shop-made tool 

NOTE: The press-in alignment tool must be manufactured to the specified dimensions.
Fig 5: Identifying Shop-Made Tool
G04684313Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
NOTE: In vehicles with 4MATIC, an adapter housing and internally-geared wheel are fitted in place of the rear transmission cover and three-arm flange. After removing the transfer case (28-200), proceed with item 11.

Removing and installing 

  1. Jack up vehicle at rear.
  2. Unscrew drain plug (1) from transmission and drain off oil.

    Installation note 

    Tightening torque for drain plug 14 Nm.

  3. Check oil level and correct (see Automatic transmission  ).
  4. Detach exhaust system at the plug connection (arrows) and remove with shielding plate.
    Fig 6: Identifying Drain Plug From Transmission And Drain Off Oil
    G04684314Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  5. Remove cross member (22) with rear engine mount.
  6. Slacken retaining strap (21).
  7. Unscrew exhaust support (34).
    Fig 7: Identifying Cross Member, Slacken Retaining Strap And Unscrew Exhaust Support
    G04684315Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  8. Unscrew cable (20) on kickdown solenoid valve (61). Unscrew bolt at pulse generator (24) and pull out pulse generator.
    NOTE: In vehicles with mechanical speedometer, seal off shaft.
  9. Unscrew flexible disk (25) on joint flange, slacken propeller shaft clamping nut and compress propeller shaft as much as possible.

    Installation note 

    Tighten propeller shaft clamping nut securely to 30 - 40 Nm.

    Fig 8: Identifying Pulse Generator And Flexible Disk
    G04684316Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  10. Select parking lock.
  11. Unscrew twelve-point collared nut (62) and pull off propeller flange (64) or internal gear (64a).

    Installation note 

    Tightening torque 120 Nm, then knock collar into depression on drive shaft (arrow) using a suitable drift.

    Fig 9: Identifying Unscrew Twelve-Point Collared Nut And Pull Off Propeller Flange
    G04684317Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  12. Remove washer (65).
  13. Unscrew combined bolts and washers (71) and pull off rear cover (70) or adapter housing.

    IMPORTANT

    When removing the rear cover (70) or adapter housing, ensure that the kickdown solenoid valve is not damaged. If necessary, slacken the kickdown solenoid valve and rotate a little.

    Installation note 

    Check gasket for damage. Generally, it may be used several times but must not be coated with sealing compound. Screw in combined bolts with washers (71) and tighten to 13 Nm (8.8) or 28 Nm (10.9).

    NOTE: Degrease bolts and coat with non-hardening sealing compound.
    Fig 10: Identifying Rear Cover And Combined Bolts With Washers
    G04684318Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Dismantling and assembling 

  14. Press out radial sealing ring (66) using a screwdriver.

    Installation note 

    Knock in using a suitable drift.

    Fig 11: Identifying Radial Sealing Ring
    G04684319Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  15. Take out circlip (68) and knock out single- row deep-groove ball bearing (67).

    Installation note 

    There must be no clearance between the circlip (68) and the single-row deep-groove ball bearing (67). For this reason, circlips are available in 3 different thicknesses (2.0 - 2.1 - 2.2 mm).

    When inserting the circlip, ensure that it is correctly seated in the groove. If the circlip cannot be inserted, a thinner circlip must be used. If there is play between the circlip and the single-row deep-groove ball bearing, a thicker circlip must be inserted.

    Fig 12: Identifying Circlip And Single-Row Deep-Groove Ball Bearing
    G04684320Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Use a feeler gauge (0.10 mm) to check whether there is clearance.

    Fig 13: Identifying Feeler Gauge
    G04684321Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  16. Remove drive gear (129) for mechanical speedometer. Remove circlip (131) and take out shaft (130) and drive gear (129).
    Fig 14: Identifying Drive Gear Circlip And Take Out Shaft
    G04684322Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  17. Pull radial seal ring (132) out of rear cover (70).
    NOTE: In order to facilitate removal, a hexagon bolt M12 can be screwed into the radial seal ring and clamped in a vise. The radial seal ring is removed by gently tapping the transmission cover with a plastic mallet.
    Fig 15: Identifying Radial Seal Ring And Out Of Rear Cover
    G04684323Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Installation note 

    Press in radial seal ring (132) carefully up to the stop using the shop-made alignment tool.

    Fig 16: Identifying Radial Seal Ring
    G04684324Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  18. A new plastic bushing (69) with O-ring (arrow) must be installed in vehicles with electronic speedometer, insert the plastic bushing using the shop-made press-in alignment tool.
    Fig 17: Identifying Plastic Bushing With O-Ring
    G04684325Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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