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Home >> Mercedes Benz >> 2008 >> GL320 4WD >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Transmission -- Testing & Repair -- 164 Chassis >> Testing & Repair >> Remove/install transmission with torque converter - AR27.10-P-0500 >> Remove/install transmission with torque converter - AR27.10-P-0500GZ (ML500)

Remove/install transmission with torque converter - AR27.10-P-0500GZ (ML500)

TRANSMISSION 722.9 in MODEL 164 with ENGINE 113, 642, 629 

Shown on model 164.175 with offroad package code 430 

Fig 1: Identifying Transmission With Torque Converter Components - Shown On Model 164.175
G05257873Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 164.175 with offroad package code 430 

Fig 2: Identifying Transmission With Torque Converter Components - Shown On Model 164.175
G05257874Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 164.175 with offroad package code 430 

Fig 3: Identifying Transmission With Torque Converter Components - Shown On Model 164.175
G05257875Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES

25.6.07 Observe tightening procedure when assembling propeller shaft, added Operation step 7, 20.1  
REMOVINGINSTALLING Remove/install    
NOTES Information on preventing damage to electronic components due to electrostatic discharge   AH54.00-P-0001-01A
NOTES Notes on bolted connections with self tapping screws   AH00.00-P-0007-01SF
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
NOTES Before starting work the area surrounding the oil cooling lines (14a, 14b) must be thoroughly cleaned in the area of the separation points of the transmission (15). Even the smallest dirt particles in the hydraulic components can lead to malfunctions and a total failure of the transmission (15)    
1 Move DIRECT SELECT gear selector switch to position "N"    
2 Release parking brake    
3 Disconnect battery ground cable   AR54.10-P-0003GZ
NOTES Notes on battery   AH54.10-P-0001-01A
4 Secure vehicle on the lifting platform and raise   AR00.60-P-0100GZ
5 Remove complete exhaust system Engine 113 AR49.10-P-7000GZ
    Engine 629, 642 AR49.10-P-7100GZB
6 Unscrew bolts (1) and nuts (2), remove shields of rear propeller shaft (3) IMPORTANT Remove all three shields completely.  
7 Detach rear propeller shaft (3) from transfer case (5) IMPORTANT Mark rear propeller shaft (3) relative to propeller shaft flange.  
    IMPORTANTInstallation:  Observe tightening procedure for rear propeller shaft (3) to transfer case (5). AR41.10-P-0050-17GZ
    SPECIAL TOOL Fig 5
    TORQUE SPECIFICATION *BA41.10-P-1001-01F 
8 Remove heat shield (6) Vehicles with Offroad package code 430  
9 Disconnect electrical connectors (6a) at transfer case (5) Vehicles with Offroad package code 430
IMPORTANT Three connectors.		  
10 Detach automatic transmission/intelligent servo module connector (X22/6) on intelligent servo module for DIRECT SELECT (A80)    
11 Remove exhaust bracket (29) On engine 113  
12 Remove shield (8) at transmission (15).   AR27.40-P-0700-01GZ 
    TORQUE SPECIFICATION *BA27.40-P-1003-01E 
13 Unplug transmission connector (9) at electric controller unit IMPORTANTInstallation:  Fix wiring harness to transmission housing using cable strap. The wiring harness must not be allowed to come into contact with the exhaust system.  
14 Remove cover (7) and remove torque converter (24) from driven plate NOTES For unscrewing and screwing in the bolts, do not use any impact wrench/driver or compressed air tool, otherwise the threaded unions in the torque converter (24) or in the driven plate will be damaged.  
    Engine 113 AR27.20-P-0100-01GZ 
    Engine 629, 642 AR27.20-P-0100-01A 
    SPECIAL TOOL Fig 8
    SPECIAL TOOL Fig 9
    TORQUE SPECIFICATION *BA27.20-P-1002-01C 
15 Remove oil cooler line bolt (10) at oil pan bracket (11). TORQUE SPECIFICATION *BA27.55-P-1003-01D 
16 Remove double hose clamp bolt (12) at alternator bracket (13). TORQUE SPECIFICATION *BA27.55-P-1004-01D 
17 Detach oil cooler line (14a) and oil cooler line (14b) from transmission (15) and engine oil pan and place to one side IMPORTANT Do not bend or kink oil cooler lines (14a, 14b).
IMPORTANT Seal the connections at the transmission (15) and oil cooler lines (14a, 14b) immediately using stop plugs.
IMPORTANTInstallation:  Replace O-rings.		  
    TORQUE SPECIFICATION *BA27.55-P-1002-01D 
    SPECIAL TOOL Fig 4
18 Support transmission (15) with transmission jack and plate IMPORTANT Lower transmission (15) slightly and fasten to transmission platform using tensioning strap.
Transmission platform, refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 
Transmission jack, refer to GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
19 Remove bolts (17, 18) and take off engine crossmember (16). IMPORTANT The rear engine mount remains on the transmission (15). The bolts (18) must be replaced: ↓  
    Engine 113 AR22.10-P-1170GZA
    Engine 629, 642
INSPECT Check rear engine mount for wear and damage and replace if required.		 AR22.10-P-1180GZD
20.1 Remove front propeller shaft (20) on transfer case (5) Engine 629, 642
IMPORTANT Mark front propeller shaft (20) relative to propeller shaft flange (20a).
IMPORTANT Hook front propeller shaft (20) to one side using cable ties.		  
    IMPORTANTInstallation:  Observe tightening procedure for front propeller shaft (20). AR41.10-P-0070-03GZ
    SPECIAL TOOL Fig 5
    TORQUE SPECIFICATION *BA41.10-P-1003-01F 
20.2 Remove the front prop shaft (20) On engine 113 AR41.10-P-0070GZ
21 Detach starter from transmission (15) IMPORTANT Place starter to the side with lines connected and secure to prevent it falling down.  
    TORQUE SPECIFICATION Engine 113 *BA15.30-P-1003-01A 
    TORQUE SPECIFICATION Engine 642 *BA15.30-P-1003-01N 
    TORQUE SPECIFICATION Engine 629 *BA15.30-P-1003-01C 
22 Remove transmission (15) from crankcase and engine oil pan by removing bolts (21) IMPORTANT First remove the bolt at the vent line bracket (22) and remove the vent line (23).  
    TORQUE SPECIFICATION *BA27.40-P-1001-01E 
    TORQUE SPECIFICATION *BA27.40-P-1002-01E 
23 Support front of engine at the engine oil pan On engine 629, 642  
24 Remove transmission (15) from below IMPORTANT Secure torque converter (24) to prevent it from falling out.
IMPORTANTInstallation:  Align the bores of the torque converter (24) with the bores in the driven plate.		  
25 Remove torque converter (24) If necessary AR27.20-P-0500-01W 
    Installed height of torque converter *BE27.20-P-1001-01E 
    SPECIAL TOOL Fig 6
    SPECIAL TOOL Fig 7
INSPECT Checking     
26 Check threaded unions in the torque converter (24) or in the driven plate IMPORTANT If the threaded unions are damaged or loose the torque converter (24) or driven plate must be replaced.  
27 Install in the reverse order    
28 Fill transmission (15) with transmission oil IMPORTANT When replacing the transmission (15) or if transmission oil is drained off.
NOTES Adhere exactly to the specified work procedure and observe Specifications for Operating Fluids, otherwise the transmission (15) will be damaged.		 AR27.00-P-0270W 
29 Check transmission oil level; correct if necessary NOTES Adhere exactly to the specified work procedure and observe Specifications for Operating Fluids, otherwise the transmission (15) will be damaged. AR27.00-P-0100W 
30 Read out fault memory and erase if necessary STAR DIAGNOSIS diagnostic system  
31 Perform transmission adaptation IMPORTANT A transmission adaptation must be carried out after exchanging or repairing the transmission (15).  
DANGER 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
32 Test run engine and check transmission (15) for leaktightness and proper operation    
TEST VALUES FOR TORQUE CONVERTER

Number Designation Transmission 722.9
BE27.20-P-1001-01E Installed height of torque converter Distance to flange for transmission housing Helical screwed connection mm 9, 5
Axial screwed connection mm 19, 5
PROPELLER SHAFT

Number Designation Model 164.1/8
BA41.10-P-1001-01F Self-locking screw, front propeller shaft to transfer case (rear axle side) Stage 1 Nm 40
Stage 2 ∠° 90
BA41.10-P-1003-01F Self-locking bolt, propeller shaft to transfer case (to front axle) Stage 1 Nm 40
Stage 2 ∠° 90
TRANSMISSION OIL COOLING SYSTEM

Number Designation Transmission 722.9
BA27.55-P-1002-01D Bolt, transmission oil line to transmission housing Banjo bolt Stage 1 Nm 5
Stage 2 ∠° 90
Hexalobular bolt Nm 12
BA27.55-P-1003-01D Bolt, oil cooler line to engine oil pan Nm 12
BA27.55-P-1004-01D Bolt, dual clamp to oil line Nm 8
HOUSING

Number Designation Transmission 722.9 in model 164
BA27.40-P-1001-01E Bolt, automatic transmission to crankcase Nm 39
BA27.40-P-1002-01E Bolt, automatic transmission to engine oil pan Nm 39
BA27.40-P-1003-01E Bolt, heat shield to transmission housing Nm 8
STARTER

Number Designation Engine 642
BA15.30-P-1003-01N Bolt, starter to cylinder crankcase Nm 40
TORQUE CONVERTER

Number Designation Transmission 722.9
BA27.20-P-1002-01C Bolt, torque converter to drive plate Straight threaded connection Nm 42
Helical cut Stage 1 Nm 4
Stage 2 Nm 30
Stage 3 ∠° 90
STARTER

Number Designation Engine 113.964 in model 164
BA15.30-P-1003-01A Bolt connecting starter to crankcase Nm 40
STARTER

Number Designation Engine 601, 602, 604, 605, 606, 611, 628, 629
BA15.30-P-1003-01C Bolt for starter Nm 42
Fig 4: Identifying Set Of Stop Plugs (129 589 00 91 00)
G05257876Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Identifying Retainer Wrench (164 589 02 07 00)
G05257877Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 6: Identifying Grab Handle (168 589 00 62 00)
G05257878Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 7: Identifying Parallel Support (126 589 04 31 00)
G05257879Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 8: Identifying Wrench Socket (001 589 65 09 00)
G05257880Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 9: Identifying Long Wedge (115 589 03 59 00)
G05257881Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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