Remove/install transmission with torque converter - AR27.10-P-0500P

TRANSMISSION 722.6 in MODEL 203, 209 (except 203.02 /05 /08 /09 /22 /25 /28 /29) 

TRANSMISSION 722.9 in MODEL 203.052 /054 /056 /252 /254 /256 /752 /756, 209.354 /356 /372 /375 /376 /454 /456 /472 /475 /476 

Fig 1: Identifying Transmission With Torque Converter Removal/Install Components - Shown On Model 203 With Transmission 722.6

	Remove/install
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Before starting work, the area around the oil cooling lines (49, 50) must be thoroughly cleaned at the separation points on the transmission. Even the smallest dirt particles, introduced into the hydraulic components, can lead to malfunctions and a total failure of the transmission
1	Disconnect ground cable of battery	Model 203	AR54.10-P-0003P
		Model 209	AR54.10-P-0003Q
	Notes on battery		AH54.10-P-0001-01A
2.1	Remove air filter	Engines 111, 112 Installation:  Lightly grease rubber guides to facilitate assembly.
2.2	Remove intake air scoop	Engine 611, 612
2.3	Remove air filter housing	Engine 113.988 in model 203.076/ 276 Engine 113.987 in models 209.376 /476 as of 24.4.04	AR09.10-P-1150AC
		Engine 272 in model 203 Engine 272, 273 in model 209	AR09.10-P-1150QB
		Engine 271 in model 203, 209	AR09.10-P-1150Q
		Engine 646 in model 203, 209	AR09.10-P-1150PM
3	Remove hot film mass air flow sensor	Model 203.076/ 276 Model 209.376/ 476	AR07.07-P-1454SV
4	Detach oil filler pipe from engine
5.1	Remove lower engine compartment paneling	Vehicles with gasoline engines	AR61.20-P-1105P
5.2	Remove bottom sections of soundproofing capsule	Vehicles with diesel engines	AR94.30-P-5300P
6	Drain transmission oil from transmission oil pan	If the transmission fluid is burnt or contains abrasive particles, the oil cooling lines (49, 50) and oil cooler must be flushed to guarantee cooling efficiency: ↓ Flush out oil cooler lines and oil cooler:
		Transmission 722.6	AR27.55-P-0001A
		Transmission 722.9 Installation:  Replace sealing ring.	AR27.55-P-0001PI
			*BA27.10-P-1001-03A
7.1	Remove rear exhaust system	Refer to: Exhaust system, removal and installation of complete system:
		Engine 611.962 /612.962 in model 203 Engine 612.967 in model 209	AR49.10-P-7000PP
		Engine 646 in model 203, 209	AR49.10-P-7000PM
		Engine 612.990 in model 203	AR49.10-P-7000PF
		Engine 112 in models 203, 209 Engine 113.968 in model 209 Engine 113.987 in Model 209.376 up to 23.4.04 Engine 113.987 in model 209.476	AR49.10-P-7000PV
		Engine 111 in model 203	AR49.10-P-7000PR
		Engine 271.921 /940 /946 /948 in model 203 Engines 271.940/ 955 in model 209	AR49.10-P-7000QK
7.2	Remove complete exhaust system	Engine 271.942 in model 203, 209	AR49.10-P-7000QD
		Engine 113.987 in Model 209.376 as of 24.4.04 Engine 113.988 in model 203	AR49.10-P-7000AC
		Engine 272 in model 203	AR49.10-P-7000QB
		Engine 272, 273 in model 209
8	Remove exhaust manifold with catalytic converter	Engine 271 in model 203, 209	AR14.10-P-4095QK
9	Support transmission with transmission jack and transmission plate
10	Remove rear engine crossmember (12) with engine mount	Do not detach engine mount from rear engine crossmember (12).
		Engine 111 except 111.981, 112, 113.988, 271.921 /940 /946 /948 in model 203 Engine 112, 113, 271.940 /955 in model 209 Engine 646 in model 203, 209	AR22.10-P-1160PR
		Engine 611, 612 in model 203 Engine 612 in model 209	AR22.10-P-1160HC
		Engine 272 in model 203 Engine 272, 273 in model 209	AR22.10-P-1160QB
11	Disconnect front drive shaft section (17) from transmission	The flexible coupling remains on the front propeller shaft (17).	AR41.10-P-0050-02EA
		Installation:  Attach front propeller shaft (17) to transmission	AR41.10-P-0050-07EA
			*BA41.10-P-1001-01A
			Fig 3
12	Undo fitted sleeves of flexible coupling and slide back front propeller shaft (17)	If the fitted sleeves are jammed: ↓	AR41.10-P-0050-09DA
		Prepare drift for loosening fitted sleeves in flexible couplings.	WF58.50-P-4110-01A
13	Press off retainer (63a) using a suitable tool	Installation:  Install new retainer (63a).
14	Unhook shift rod (63) from range selector lever on transmission	Installation:  Install new retainer (63a).
15	Disconnect plug connector	Transmission 722.6	AR27.10-P-0500-01A
		Transmission 722.9	AR27.40-P-0700-01V
			*BA27.40-P-1014-01A
			*BA27.40-P-1019-01A
16.1	Unclip cover and remove bolts (95)	All transmissions except 722.9 with angled threaded connection
			*BA27.20-P-1002-01C
16.2	Unclip cover from transmission bell and remove bolts (95)	Transmission 722.9 with angled threaded connection	AR27.20-P-0100-01A
			*BA27.20-P-1001-01C
			*BA27.20-P-1002-01C
			Fig 2
			Fig 4
17	Detach pipe (21) from engine oil pan	Engines 111, 611, 612	*BA01.45-P-1001-01A
		Engine 112, 113	*BA01.45-P-1001-01B
		Engine 271	*BA01.45-P-1001-01H
		Engine 272, 273	*BA01.45-P-1007-01M
		Engine 646	*BA01.45-P-1001-01G
18.1	Detach oil cooling line (49) to oil cooler from transmission	Engine 111, 112, 113, 271, 272, 273
18.2	Disconnect oil cooling line (50) to oil cooler	Engine 611, 612, 646
19	Slacken bolt (50a)	Engine 611, 612, 646
20	Unscrew bolt (2)	Transmission 722.6:
			*BA27.40-P-1001-01B
		Transmission 722.9:	*BA27.40-P-1002-01B
			*BA27.10-P-1001-04E
			*BA27.10-P-1002-04E
21	Turn lead pipe (21) down out of the way
22	Remove transmission downwards at an angle using transmission jack and transmission platform	Secure torque converter to prevent it from falling out.
23	Remove torque converter using grab handles	If necessary
		Transmission 722.6	AR27.20-P-0500-01P
		Transmission 722.9	AR27.20-P-0500-01W *BE27.20-P-1001-01B
			Figure
			Fig 5 *BR00.45-Z-1009-06A
	Checking
24	Check threaded unions in driven plate/torque converter	If threaded unions are damaged and loose, the driven plate/torque converter must be replaced.
25	Install in the reverse order
26	Perform basic programming	Model 203	AR00.19-P-0200P
		Model 209	AR00.19-P-0200Q
27	Fill transmission with gear oil	Transmission 722.9
		Transmission 722.9: When replacing the transmission or if the transmission oil has been drained.	AR27.00-P-0270W
28	Check oil level in transmission and correct if necessary	Transmission 722.6	AR27.00-P-0101P
		Transmission 722.9	AR27.00-P-0100W
29	Read out fault memory with STAR DIAGNOSIS and erase if necessary
30	Perform transmission adaptation	After replacing or repairing transmission, perform transmission adaptation.
	Risk of accident  caused by vehicle starting off by itself when engine is running. Risk of injury  caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
31	Perform engine test run and check transmission for leaks and that it is functioning correctly

OIL PAN

OIL PAN

OIL PAN

OIL PAN

OIL PAN

OIL PAN

OIL PAN

AUTOMATIC TRANSMISSION COMPLETE

HOUSING

OIL PAN, AUTOMATIC TRANSMISSION

PROPELLER SHAFT

HOUSING

TORQUE CONVERTER

Fig 2: Identifying Socket (001 589 65 09 00)

Fig 3: Identifying Torque Wrench (001 589 66 21 00)

Fig 4: Identifying Long Wedge (115 589 03 59 00)

Fig 5: Identifying Parallel Support (126 589 04 31 00)

Fig 6: Identifying Grab Handle (168 589 00 62 00)