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Home >> Mercedes Benz >> 2002 >> SLK230 Automatic >> Repair and Diagnosis >> Transmission >> Manual Trans >> Gear Assembly, Shafts, Differential - SLK230 & SLK320 - 716.622/630/660/662/667 >> Overhaul >> Disassemble/Assemble Transmission Housing >> Assemble Transmission Housing

Assemble Transmission Housing

NOTE: The sealing surfaces must be free of oil and grease.
  1. 1 -  Apply the prescribed sealant to the contact surfaces on the front section of the transmission casing.
    2. Fig 1: Applying Sealant To Case Surfaces (1 Of 2)
    G00389356Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  2. 2 -  Coat sealing surface of rear part of transmission housing around vent cap with specified sealing compound.
    3. Fig 2: Applying Sealant To Case Surfaces (2 Of 2)
    G00389357Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  3. 3 -  Insert main shift rail (20) if necessary.
    NOTE: Ensure that shift unit is in correct position (arrows).
    4. Fig 3: Assembling Transmission Housing (1 Of 11)
    G00389358Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  4. 4.1 -  Tighten SEQ gearshift lever (17) with bolt (9) to main shift rail (20) and tighten with bolts (18) to transmission housing rear section.
    NOTE: Observe "top" labeling on SEQ gearshift lever.

    Use Automated manual transmission gear shift lever (tool). See Fig 14.

    5. Fig 4: Assembling Transmission Housing (2 Of 11)
    G00389359Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  5. 5 -  Oil cylinder roller bearing in the drive shaft.
  6. 6 -  Guide the transmission casing rear section (6) with the transmission shafts (7) into the casing front section.
    NOTE: Slightly raise countershaft from front.
    NOTE: The drive shaft, countershaft, main shift shaft, and guides of the shift unit must slot together.
    7. Fig 5: Assembling Transmission Housing (3 Of 11)
    G00389360Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  7. 7 -  Fit transmission housing rear section with two 60 mm long bolts (5) onto the holes with guide sleeves.

    Tighten rear section of transmission housing finger-tight.

    8. Fig 6: Assembling Transmission Housing (4 Of 11)
    G00389361Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  8. 8 -  Position bolt (4) and screw in finger-tight
    9. Fig 7: Assembling Transmission Housing (5 Of 11)
    G00389362Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

  9. 9 -  Attach insertion tool (3) to drive shaft and screw nut (2) down to lowest position.

    Use Insertion tool (716 589 04 33 00). See Figure.

    10 -  Install wedges (1). See Fig 7.

    11 -  Screw nut (2) upwards until wedges touch.

    12 -  Position retainer wrench (8) on nut.

    Use Retainer wrench (716 589 00 09 00). See Figure.

    10. Fig 8: Assembling Transmission Housing (6 Of 11)
    G00389363Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  10. 13 -  Install countershaft with bolt and drive shaft using retaining wrench (8) alternately and uniformly until retaining wrench (8) also rotates when countershaft is drawn in.
    CAUTION: DO NOT use electric or impact wrenches.
  11. 14 -  Tighten nut using retaining wrench (8).

    Use Retainer wrench (716 589 00 09 00). See Figure.

  12. 15 -  Use retaining wrench (8) to loosen nut again and remove insertion tool.
  13. 16 -  Unscrew 60 mm long bolts (arrows) and tighten transmission housing rear section with NEW bolts (5). See Fig 9 and Fig 10 .

    Torque specification: TRANSMISSION HOUSING .

    14. Fig 9: Assembling Transmission Housing (7 Of 11)
    G00389364Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 10: Assembling Transmission Housing (8 Of 11)
    G00389365Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  14. 17 -  Sequentronic automated manual transmission (SEQ):
  15. 17.1 -  Shift through gears.
  16. 17.2 -  Remove SEQ gearshift lever.
  17. 18 -  Install radial shaft sealing ring (11) using drift.
    18. Fig 11: Assembling Transmission Housing (9 Of 11)
    G00389366Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  18. 19 -  Fit on output flange (10).
    NOTE: Transmission versions for passenger cars have three-arm flange.
  19. 20 -  Tighten new collared nut (9). When doing so, counterhold using pin wrench.
    NOTE: Special tool assignment: Cars: Pin wrench and socket wrench bit.

    Use Pin wrench (129 589 01 07 00). See Figure.

    Use Socket wrench bit (126 589 02 09 00). See Figure.

    Torque specification: See COMPLETE MANUAL TRANSMISSION .

  20. 21 -  Lock collared nut using drift.
  21. 22 -  Tighten the bolt (12) of the countershaft.
    NOTE: Counterhold using Retainer wrench (13).

    Use Retainer wrench (716 589 00 09 00). See Figure.

    Torque specification: See GEAR ASSEMBLY, SHAFTS .

    22. Fig 12: Assembling Transmission Housing (10 Of 11)
    G00389367Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  22. 23 -  Determine thickness of the circlip (15):
    • Insert test ring (thickness: 1.5 mm) and press all the way down (direction toward output end).
    • Measure distance between test ring and nut upper edge of drive shaft with feeler gage.
    • Thickness of circlip = measured value + 1.5 mm (test ring).
    • Remove test ring.
    23. Fig 13: Assembling Transmission Housing (11 Of 11)
    G00389368Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  23. 24 -  Use pliers to insert new circlip (15) of the calculated thickness (graduation: 0.05 mm).
    NOTE: Ensure that the circlip is properly seated.
  24. 25 -  Install radial shaft seal (16) with drift punch.
    NOTE: Use appropriate drift.

    Drift (716 589 01 15 00). See Figure.

    Drift (210 589 04 15 00). See Figure.

  25. 26 -  Install counter shaft seal cover (14) with drift punch.
    NOTE: Use appropriate drift.

    Drift (716 589 01 15 00). See Figure.

    Drift (210 589 04 15 00). See Figure.

Fig 14: Automated Manual Transmission Gear Shift Lever
G00389371Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TORQUE SPECIFICATION TRANSMISSION HOUSING

Designation Transmission 716.643 Transmissions 716.60/62/ 640/641/ 644/66 Transmission 716.604/ 634/649/ 651
Bolt of front section of transmission housing to rear section of transmission housing Nm 28 28 28
TORQUE SPECIFICATION GEAR ASSEMBLY, SHAFTS

Designation Transmission 716.60/62/ 63 Transmission 716.64/ 65/66
Countershaft bolt M14x 1.5 Nm 75 -
M18x1.5 Nm - 100
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