Dismantling and assembling transmission - RA2703722C640X(27-640)

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

27-4010

Assembling 

Before installing, immerse new brake bands and lining discs of multiple-disc brake in ATF for approx. 1 hour.

1. 55 Place housing (1) into assembly device and secure in place with the bolt (arrow).
   Fig 1: Identifying Housing Bolt

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. 56 Insert plastic guide ring (88a) for plunger B2, then insert lip sealing ring (88) using the shop-made drift. The sealing lip (arrow) must point in the direction of the brake band plunger cover.
   Fig 2: Identifying Plastic Guide Ring And Lip Sealing Ring

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
   NOTE: The impact drift must be manufactured in accordance with the specified dimensions.
   Fig 3: Identifying Drift Specified Dimensions

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. 57 Place O-ring (91) in groove.
4. 58 Insert radial sealing ring (92).
5. 59 Screw in screw plug (90) with new aluminum sealing ring and tighten to 10 Nm.
   Fig 4: Identifying Screw Plug, Radial Sealing Ring And O-Ring

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6. 60 Place O-ring (arrow) in groove.
   Fig 5: Locating O-Ring

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7. 61 Coat grooves in support flange K2 (79) with grease. Insert Teflon rings (115) and push into the groove so that the diagonal cut (arrow) remains closed.
   Fig 6: Identifying Support Flange And Teflon Rings

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. 62 Insert support flange (79) following the pattern of holes for the retaining bores; use two bolts, approx. 80 mm long, for centering.
9. 63 Screw in combined bolts and washers (114) and tighten to 11 Nm.
   Fig 7: Identifying Hexagon Bolts And Support Flange

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
10. 64 Check thrust element B2 for twisting. With the thrust element removed, the bore and tab (arrows) must align. With the thrust element installed, one spring winding of the thrust element must be visible through the bore for the lower cover oil pipe.
    Fig 8: Locating Check Thrust Element

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
11. 65 Insert thrust element B2 (29) with the tab (arrow) upwards.
    NOTE: Use of pressure element B2 (29) with increased spring force.

    Vehicles with M 117/119 as of transmission no. 3 305 965

    Other vehicles as of transmission no. 3 307 060

    Fig 9: Identifying Thrust Element B2

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
12. 66 Insert support ring (113) in such a way that the lug for the anti-rotation element (arrow) is located in the housing.
    NOTE: As of 08/94, an axial bearing is installed instead of the support ring (113).
13. 67 Re-check seating of Teflon rings on support flange (79).
    Fig 10: Identifying Support Ring And Support Flange

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
14. 68 Compress brake band B2 (27) at the support lugs as far as possible and insert in housing. To facilitate assembly, the brake band may be held together with the aid of the locking device (23).
    NOTE: As of 10/89, use of brake band B2 (27) with Raybestos coating for improved shifting quality.
    Fig 11: Identifying Compress Brake Band B2 And Locking Device

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15. 69 Attach clutch K2 (100) onto gear set.
    Fig 12: Identifying Clutch K2

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16. 70 Insert gear set in transmission housing whilst rotating drive shaft (87).
17. 71 Position transmission vertically with drive shaft (87) uppermost.
    Fig 13: Identifying Drive Shaft

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18. 72 Check installed position of gear set. The gear set is correctly installed when the top edge of the connecting member (arrow) is lower than the bearing surface (138) of the outer multiple-disc LB3.
19. 73 Assemble front cover with primary pump (27-630) .
20. 74 Insert damping spring (134).
    Fig 14: Identifying Damping Spring And Bearing Surface

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    NOTE: As of transmission no. 3 716 425 an additional plastic washer is fitted.
21. 75 Assemble discs for multiple-disc brake LB3 in the sequence illustrated in the figure and insert individually.
    NOTE: As of transmission no. 3 991 611, use of disk spring (85) with increased stroke.
    Fig 15: Identifying Multiple-Disc Brake Components

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
22. 76 Measure clearance "L" of multiple-disc brake LB3 and compensate.

    Measuring distance "a" 

    Place parallel-edged block (029) on the machined surface and measure depth to outside edge of spring seat (85) using a depth gauge.

    Fig 16: Measuring Clearance "L" Of Multiple-Disc Brake Lb3 And Compensate

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Determining distance "b" 

    Place parallel-edged block (029) on plunger of multiple-disc brake (arrows) and measure depth to gasket (11) using a depth gauge.

    The clearance "L" is the difference between the two measurements.

    Adjust clearance "L" to its specified value of 1.5 - 2.0 mm. Variations can be compensated by means of the outer multiple-discs available in different thicknesses (133a, illustration item 75).

    Fig 17: Identifying Depth To Gasket Distance

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
23. 77 Coat groove in driveshaft (87) with grease. Insert lubricating pressure ring (99) and push into groove so that the gap remains closed.
    Fig 18: Identifying Driveshaft And Pressure Ring

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
24. 78 Engage assembly lock (arrow) on brake band B1 (30).
    Fig 19: Locating Brake Band B1

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
25. 79 Insert clutch K1 (83) whilst rotating so that the splines engage.
26. 80 Insert brake band B1 (30) so that the pin of the assembly lock (arrow, figure to item 78) points towards thrust element B1.
    Fig 20: Identifying Clutch K1

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
27. 81 Replace O-rings. Then insert thrust element B1 (31) with pressure pin and screw in screw plug (33) or overload protection switch (33b) and tighten to 70 Nm.
    Fig 21: Identifying Thrust Element B1, Screw Plug And Overload Protection Switch

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
28. 82 Insert brake band guide (34) ensuring that the locating pins engage in the bores in the housing and press it in until it locks in position detectably.
    Fig 22: Identifying Brake Band Guide

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
29. 83 Measure axial play "B" for clutch K1 and correct.

    Axial play "B": 0.6-1.0 mm.

    Position seal (19) on front cover (10).

    Fig 23: Locating Axial Play

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Place parallel-edged block (029) on flange (arrow).

    Measure from parallel-edged block to gasket (11) using depth gauge (distance "b").

    Fig 24: Measuring From Parallel-Edged Block To Gasket

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Place parallel-edged block (029) on machined surface of transmission housing. Measure from parallel-edged block to contact surface in clutch K1 (83) using depth gauge (distance "a").

    Fig 25: Identifying Transmission Housing Distance

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Hold shim (95), thrust washer (96) and axial bearing (97) together and measure distance "c" using caliper gauge.

    Distances "b" and "c" subtracted from distance "a" equal the axial play "B" of clutch K1. The axial play can be adjusted by inserting appropriate shims

    (95, thickness 0.1, 0.2, 0.5 mm).

    Fig 26: Identifying Distances "C"

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
30. 84 Insert measured shims, friction ring and axial bearing one by one into clutch K1 (see figure item 83).
31. 85 Insert Teflon rings (9) with grease. Ensure that the gap in rings (arrows) remains closed. If necessary, remove rings again and shape to a smaller diameter.
    Fig 27: Locating Teflon Rings

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
32. 86 Insert front cover (10) with gasket, tighten bolts (18) to 13 Nm.
    NOTE: The gasket may be used several times but must never be coated with sealing compound. In contrast, the combined bolts and washers (18) must be lightly coated with non-hardening sealing compound.
    Fig 28: Identifying Front Cover

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
33. 87 Rotate assembly device until output shaft (86) points upwards. Push snap ring (116) along output shaft as far as its groove
    Fig 29: Identifying Output Shaft And Snap Ring

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
34. 88 Attach helical gear (78).
    Fig 30: Identifying Helical Gear

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
35. 89 Insert axial retainer (43) in transmission housing.
36. 90 Insert O-ring (48).
37. 91 Insert centrifugal governor (50).
38. 92 Swivel axial retainer (43) towards centrifugal governor (50) so that it engages in the groove in the governor shaft (arrow).
    Fig 31: Locating Governor Shaft

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
39. 93 Insert cover (46) and attach circlip (47) with the aid of a screwdriver. Then pull cover outwards so that it contacts the circlip around its entire circumference.
    Fig 32: Identifying Cover And Circlip

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
40. 94 Insert intermediate plate (21) and O-ring (22).
    Fig 33: Identifying Intermediate Plate And O-Ring

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
41. 95 Attach secondary pump (20) and tighten hexagon socket bolts (45) to 8 Nm.
42. 96 Check seating of axial bracket again, screw on nut (44) and tighten to 6 Nm.
    Fig 34: Identifying Secondary Pump And Hexagon Socket Bolts

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
43. 97 Insert oil pipe (84) and tighten hexagon socket bolt (84a) to 8 Nm.
    NOTE: Oil pipe (84) not used any more as of transmission no. 3 234 346.
    Fig 35: Identifying Oil Pipe And Hexagon Socket Bolt

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
44. 98 Insert detent plate (82) with spring linkage and push in shaft (76).
45. 99 Screw in hexagon socket bolt (82a) and tighten to 8 Nm.
    Fig 36: Identifying Detent Plate And Hexagon Socket Bolt

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
46. 100 Push roller (81) onto spring linkage (82).
47. 101 Attach plastic guide (80) and push into locating bores.
    Fig 37: Identifying Spring Linkage, Roller And Plastic Guide

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
48. 102 Place shims (77) onto helical gear.
    Fig 38: Identifying Shims Onto Helical Gear

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
49. 103 Push on parking lock pawl (74), insert expanding spring (75) and hook onto parking lock pawl (74).
    Fig 39: Identifying Expanding Spring And Hook Onto Parking Lock Pawl

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
50. 104 Mount parking lock gear (73) with rotor or helical gear.
    Fig 40: Identifying Parking Lock Gear With Rotor Or Helical Gear

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
51. 105 Measure axial play (C) of output shaft (clutch K2) and correct.
    Fig 41: Identifying Axial Play Of Output Shaft (Clutch K2)

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Attach measuring sleeve (028) and tighten collared nut (62) to 100 Nm. Engage the parking lock pawl (arrow) to counter the nut. Attach seal (72).

    Fig 42: Locating Parking Lock Pawl

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Position parallel-edged block (029). Measure depth from measuring sleeve (028) to block using depth gauge. Add 15 mm to the measured distance to obtain distance "b".

    NOTE: The 15 mm is the height of the parallel-edged block (20 mm) minus the edge of the measuring sleeve (5 mm). Assemble rear cover (27-440) .
    Fig 43: Identifying Parallel-Edged Block Position

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Place parallel-edged block (029) on the sealing surface of rear cover.

    Measure from parallel-edged block (029) to the inside ring of the ball bearing using a depth gauge. Subtract 20 mm from the measured distance to obtain distance "a".

    Distance "a" minus distance "b" equals the axial play "C".

    Correct the axial play "C" to 0.4+01 mm by adding or removing shims (77) below the parking lock gear (73) (see figure to item 102).

    Fig 44: Measuring Parallel-Edged Block To Inside Ring Of Ball Bearing

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
52. 106 Push seal (arrow) onto oil pipe (102) for (mechanical) speedometer lubrication and insert oil pipe.
    Fig 45: Locating Seal Onto Oil Pipe

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
53. 107 Mount rear cover (70), coat hexagon bolts (71) with non-hardening sealing compound and tighten to 13 Nm (8.8) or 28 Nm (10.9).
    NOTE: The gasket may be used several times but must never be coated with sealing compound.
54. 108 Insert washer (65).
    Fig 46: Identifying Rear Cover And Hexagon Bolts

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
55. 109 Insert O-ring (63) into propeller flange (64).
    Fig 47: Identifying O-Ring Into Propeller Flange

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
56. 110 Attach propeller flange (64), tighten double-hexagon collared nuts (62) to 120 Nm and lock in place with a suitable drift.
57. 111 Screw in kickdown solenoid valve (61) and tighten to 20 Nm.
    Fig 48: Identifying Propeller Flange And Solenoid Valve

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
58. 112 Insert modulating pressure regulator valve (59) and pressure pin (59a).
59. 113 Mount vacuum unit (60) with retaining plate (57) and tighten hexagon socket bolts (58) to 8 Nm.
    Fig 49: Identifying Modulating Pressure Regulator Valve And Pressure Pin

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
60. 114 Mount starter lock-out switch (53), screw in hexagon bolts (55) but do not tighten.
    Fig 50: Identifying Starter Lock-Out Switch And Hexagon Bolts

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
61. 115 Insert lip sealing ring (39) at brake band plunger B1 (37) so that the sealing lip points towards the outside.
    Fig 51: Identifying Shims Dimension

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
62. 116 Mount assembly device (026) and bolt on transmission housing.
63. 117 Insert brake band plunger B1 with one pressure spring and measuring device (031).
64. 118 Screw in spindle of assembly device (026) ensuring that pressure pin of brake band plunger B1 is inserted in brake band and that lip seal is not damaged.
    NOTE: To adjust the clearance, it is sufficient for just one pressure spring to be installed.
    Fig 52: Identifying Assembly Device And Bolt On Transmission Housing

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
65. 119 Insert circlip (41), release assembly device (026) and remove.
    Fig 53: Identifying Circlip And Assembly Device

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    NOTE: In order to be able to remove and install the circlip (41) without slackening the screw plug or transmission overload protection switch, a chamfer (arrow) must be cut on 1st version measuring devices.
    Fig 54: Locating Chamfer

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
66. 120 Measure clearance "L" at brake band B1 and adjust.
    NOTE: The thread on the measuring device (031) has 1 mm pitch, i.e. one revolution corresponds to 1 mm travel.

    Screw in bolt on measuring device (031) by hand until resistance is detectable.

    Fig 55: Identifying Measuring Device

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Using a torque wrench, screw in the bolt further, counting the revolutions, and tighten bolt to 1 Nm.

    The idle travel at the brake band must be 1.8 - 2.0 mm, i.e. a torque of 1 Nm must be achieved after 1.8 - 2.0 revolutions.

    Fig 56: Identifying Torque Wrench

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    The clearance can be adjusted by inserting or removing shims (136) in the pressure pin (38).

    Fig 57: Identifying Shims Dimension

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
67. 121 Reattach assembly device and bolt in place. Install brake band plunger cover (40) and second compression spring in place of measuring device, then remove assembly device.
    Fig 58: Identifying Brake Band Plunger

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Brake band plunger B1 2nd version with automatic adjuster as of transmission no. 3 746 852

    Fig 59: Identifying Brake Band Plunger Components Location

    Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Illustration 1