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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 >> Notes

Disassemble/Assemble Transmission Housing: Notes

Transmission 716.660 In Model 170.465 Except Code (424) Sequentronic (SEQ) Manual Transmission. 

Transmission 716.622 In Model 170.444/449, 203.045, 208.344/444, 210.048/248 Except Code (424) Sequentronic (SEQ) Manual Transmission. 

Fig 1: Disassembling & Assembling Transmission Housing
G00389256Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove 

    WARNING: Risk of explosion caused by explosive gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead acid batteries No fire, sparks, open flames or smoking. Wear protective gloves, acid-resistant clothing and safety glasses. Pour battery acid only into suitable and appropriately marked containers.
    NOTE: Always disconnect the negative terminal first (at battery terminal or at chassis ground) and then the positive terminal. Upon installation the positive terminal is connected first (if removed).
  1. 1 -  Disconnect ground lead from battery, Model 170. See DISCONNECT GROUND LEAD FROM BATTERY .

    Notes on battery. See NOTES ON BATTERY

  2. 2 -  Unscrew oil drain screw (3) and drain oil. See Fig 1.
  3. 3 -  Remove transmission. See REMOVE/INSTALL TRANSMISSION .

Disassemble 

  1. 4.1 -  Remove dowel pins at flange of front section of transmission housing (with in-line engine).
  2. 5 -  Attach transmission to assembly stand. See FASTEN TRANSMISSION ON ASSEMBLY STAND in HOUSING article.
  3. 6 -  Remove central clutch release bearing. See REMOVE/INSTALL CENTRAL CLUTCH RELEASE BEARING in HOUSING article.
  4. 7 -  Remove radial shaft sealing ring (11) of input shaft (13) and sealing cover (10) of countershaft (12).
  5. 8 -  Remove circlip (8) on input shaft using pliers. See Fig 1.

    Use Pliers (000 589 52 37 00). See Fig 4.

  6. 9 -  Unscrew bolt (9) on countershaft (12).
    NOTE: To do this, counterhold input shaft (13) using retainer wrench.

    Use Retainer wrench (716 589 00 09 00). See Fig 5.

  7. 10.1 -  Remove reverse gear lock (6).

    For removing the gear sets.

    Use Impact extractor (602 589 00 33 00). See Fig 6.

    Use Extraction claw (716 589 03 33 00). See Fig 7.

  8. 11 -  Remove connection piece (14) from shift rod; for this step, remove roll pin (15). See Fig 1. Also, see REMOVING/INSTALLING SECURING PIN in GEARSHIFT article.

    Use Extraction and insertion tool (210 589 06 33 00). See Fig 8.

  9. 12 -  Remove output shaft (2).

    When doing so, counterhold using socket screw wrench.

    Use Pin wrench (129 589 01 07 00). See Fig 9.

    Use Socket wrench bit (126 589 02 09 00). See Fig 10.

  10. 13 -  Position the transmission horizontal and unscrew bolts (7). See Fig 1.
  11. 14 -  Screw in two safety bolts (arrows, length approximately 60 mm) several threads in the positions shown.
  12. 15 -  Position transmission vertically.
  13. 16 -  Drive out countershaft (12) using plastic mallet.
  14. 17 -  Position the transmission horizontal and unscrew the safety bolts (arrows).
  15. 18 -  Remove rear part of transmission housing (5) together with wheel sets.

    Disassemble and assemble rear section of transmission housing. See DISASSEMBLE AND ASSEMBLE REAR SECTION OF TRANSMISSION HOUSING .

    Disassemble and assemble front section of transmission housing. See DISASSEMBLE AND ASSEMBLE FRONT SECTION OF TRANSMISSION HOUSING .

  16. 19 -  Remove main shaft and countershaft with shift unit. See REMOVE MAIN SHAFT AND COUNTERSHAFT WITH SHIFT UNIT .

    Use Assembly template (210 589 01 31 00). See Fig 11.

    Use Assembly template (716 589 00 31 00). See Fig 12.

    Use Puller (000 589 65 33 00). See Fig 13.

    Use Claw (000 589 87 33 00). See Fig 14.

  17. 20 -  Press out input shaft (13). See Fig 1.
    NOTE: It is absolutely essential (13) to remove the input shaft as the gear sets and shift unit can only be installed together with the input shaft (13).

Assemble 

  1. 21 -  Assemble main shaft and countershaft (12) with shift unit. See Fig 1. Also, see INSTALLING MAIN SHAFT WITH COUNTERSHAFT WITH SHIFT UNIT .

    Use Assembly template (210 589 01 31 00). See Fig 11.

    Use Assembly template (716 589 00 31 00). See Fig 12.

    Use Pulling-in sleeves (716 589 00 33 00). See Fig 15.

  2. 22 -  Assemble transmission housing. See ASSEMBLE TRANSMISSION HOUSING .

    Upon installation: The separating surfaces must be free of oil and grease, clean with a plastic wedge and coat with sealing compound.

    Torque specification: Bolt, front section of transmission housing to rear section of transmission housing. See TRANSMISSION HOUSING .

    Torque specification: Nut for out put flange on mainshaft. See COMPLETE MANUAL TRANSMISSION .

    Torque specification: Countershaft bolt. See GEAR SET, SHAFTS .

    Recommended tools:

    • Use Insertion tool (716 589 04 33 00). See Fig 16.
    • Use Retainer wrench (716 589 00 09 00). See Fig 5.
    • Use Drift (210 589 03 15 00). See Fig 17.
    • Use Pin wrench (129 589 01 07 00). See Fig 9.
    • Use Socket wrench bit (126 589 02 09 00). See Fig 10.
    • Use Drift (716 589 01 15 00). See Fig 18.
    • Use Drift (210 589 04 15 00). See Fig 19.
    • Use Pliers for external circlip. See Fig 20.

    Use LU cleaner. See Fig 21.

    Use Sealant. See Fig 21.

  3. 23 -  Drive in latching device for reverse gear (6) up to rabbet.
  4. 24 -  Push connection piece (14) onto shift rod and secure with roll pin (15). See Fig 1. Also, see REMOVING/INSTALLING SECURING PIN in GEARSHIFT article.

    Use Extraction and insertion tool (210 589 06 33 00). See Fig 8.

  5. 25 -  Install central clutch release bearing. See REMOVE/INSTALL CENTRAL CLUTCH RELEASE BEARING in HOUSING article.
  6. 26 -  Screw in oil drain plug (3). See Fig 2.
  7. 27 -  Unscrew oil filler plug (4). See Fig 2.
  8. 28 -  Fill with transmission oil.
    NOTE: The transmission must be in the installation position.
    NOTE: Correct oil level =10 mm below bottom edge of filler hole.
    NOTE: Carry out measurement e.g. with angled hexagon socket wrench

    Fluid capacity: See Fig 3.

    NOTE: Filling capacity of transmission oil revised. See ON VEHICLE SERVICING .
  9. 29 -  Screw in oil filler plug (4).
  10. 30 -  Remove transmission from assembly stand.
  11. 30.1 -  Knock dowel pins into flange of front section of transmission housing.

    With in-line engine.

Install 

  1. 32 -  Install transmission. See REMOVE/INSTALL TRANSMISSION .
  2. 33 -  Connect ground lead to battery. See DISCONNECT GROUND LEAD FROM BATTERY .
    NOTE: Upon installation the positive terminal is connected first (if removed).
    NOTE: Code radio, set clock, normalize window regulator, and set timer for stationary heater (if equipped).
TORQUE SPECIFICATION TRANSMISSION HOUSING

Designation Transmission 716.643 Transmissions 716.60/62/ 640/641/ 644/66 Transmission 716.604/ 634/649/ 651
Bolt for front section of transmission housing to rear section of transmission housing Nm 28 28 28
TORQUE SPECIFICATION COMPLETE MANUAL TRANSMISSION

Designation Transmission 716.60/62/63/ 64/66
Collar nut, output flange to main shaft M26 Nm 160
TORQUE SPECIFICATION GEAR SET, SHAFTS

Designation Transmission 716.60/62/ 63 Transmission 716.64/ 65/66
Countershaft bolt M14 x 1.5 Nm 75 -
M18 x 1.5 Nm - 100
Fig 2: Torque specification: Oil Drain Plug & Oil Filler Screw
G00389278Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Transmission Complete Fluid Level Filling Capacity
G00389279Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Pliers (000 589 52 37 00)
G00389257Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Retainer Wrench (716 589 00 09 00)
G00389258Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 6: Impact extractor (602 589 00 33 00)
G00389259Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 7: Extraction claw (716 589 03 33 00)
G00389260Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 8: Extraction and insertion tool (210 589 06 33 00)
G00389261Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 9: Pin wrench (129 589 01 07 00)
G00389262Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 10: Socket wrench bit (126 589 02 09 00)
G00389263Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 11: Mounting Plate (210 589 01 31 00)
G00389264Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 12: Mounting Plate (716 589 00 31 00)
G00389265Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 13: Puller (000 589 65 33 00)
G00389266Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 14: Claw (000 589 87 33 00)
G00389267Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 15: Insertion Sleeves (716 589 00 33 00)
G00389268Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 16: Insertion Tool (716 589 04 33 00)
G00389269Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 17: Drift (210 589 03 15 00)
G00389270Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 18: Drift (716 589 01 15 00)
G00389271Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 19: Drift (210 589 04 15 00)
G00389273Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 20: Commercially Available Tool (External Circlip Pliers)
G00389274Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 21: Auxiliary Repair Materials (Cleaner & Sealant)
G00389272Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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