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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-0500GZS (ML63 AMG)

Remove/install transmission with torque converter - AR27.10-P-0500GZS (ML63 AMG)

TRANSMISSION 722.9 in MODEL 164, 251 with ENGINE 156 

Fig 1: Identifying Transmission With Torque Converter Components (1 Of 3)
G05257891Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Identifying Transmission With Torque Converter Components (2 Of 3)
G05257892Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Transmission With Torque Converter Components (3 Of 3)
G05257893Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES

25.6.07 Special tool for counterholding the propeller shaft modified   AR41.10-P-0070-03GZ
Observe tightening procedure when assembling propeller shaft, added Step 8
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 Model 164 AR54.10-P-0003GZ
    Model 251 AR54.10-P-0003RT
NOTES Notes on battery   AH54.10-P-0001-01A
4 Secure vehicle on the lifting platform and raise Model 164 AR00.60-P-0100GZ
    Model 251 AR00.60-P-0100RT
5 Remove exhaust system up to rear flange connection Model 164 AR49.10-P-7000GZS
    Model 251 AR49.10-P-7000RT
6 Remove bolts from the stiffening bridge under the propeller shaft Model 251 only  
    TORQUE SPECIFICATION *BA61.10-P-1005-01F 
7 Unscrew the bolts (1) and nuts (2) and remove shields of propeller shafts IMPORTANT Remove all three shields complete  
8 Detach rear propeller shaft from transfer case (5) IMPORTANT Mark the rear propeller shaft relative to the propeller shaft flange.  
    IMPORTANTInstallation:  Observe tightening procedure for rear propeller shaft to transfer case (5). AR41.10-P-0050-17GZ
    SPECIAL TOOL Fig 5
    TORQUE SPECIFICATION Model 164 *BA41.10-P-1001-01F 
    TORQUE SPECIFICATION Model 251 *BA41.10-P-1001-01G 
9 Disconnect automatic transmission/intelligent servo module connector (X22/6) from intelligent servo module for DIRECT SELECT (A80)    
10 Remove exhaust bracket (29)    
11 Remove shield (8) at transmission (15).   AR27.40-P-0700-01GZ 
    TORQUE SPECIFICATION *BA27.40-P-1003-01E 
12 Disconnect connector (9) at electric controller unit    
13 Remove cover (7) and detach torque converter (24) from drive 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. AR27.20-P-0100-01A 
    TORQUE SPECIFICATION *BA27.20-P-1002-01C 
    SPECIAL TOOL Fig 7
    SPECIAL TOOL Fig 6
14 Remove oil cooler line bolt (10) at oil pan bracket (11). TORQUE SPECIFICATION *BA27.55-P-1003-01D 
15 Remove double hose clamp bolt (12) at alternator bracket (13). TORQUE SPECIFICATION *BA27.55-P-1004-01D 
16 Detach oil cooler lines (14a, 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 on the transmission (15) and oil cooler lines (14a, 14b) immediately with stop plugs.
IMPORTANTInstallation:  replace O-rings.		  
    TORQUE SPECIFICATION *BA27.55-P-1002-01D 
    SPECIAL TOOL Fig 4
17 Support transmission (15) with transmission jack and plate IMPORTANT Lower transmission (15) slightly and secure on the transmission platform with tensioning strap to prevent it from falling down.
Transmission platform, see GOTIS
http://gotis.aftersales.daimlerchrysler.com 
Transmission jack, see GOTIS
http://gotis.aftersales.daimlerchrysler.com 		  
18 Remove bolts (17, 18) and take off engine crossmember (16). IMPORTANT The rear engine mount remains on the transmission (15). Bolts (18) must be replaced.
INSPECT Check rear engine mount for wear and replace if necessary.		 AR22.10-P-1170GZS
19 Remove front propeller shaft (20) on transfer case (5) 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 Model 164 *BA41.10-P-1003-01F 
    TORQUE SPECIFICATION Model 251 *BA41.10-P-1003-01G 
20 Detach starter from transmission (15) IMPORTANT Place starter to the side with lines connected and secure to prevent it falling down.  
    TORQUE SPECIFICATION *BA15.30-P-1003-01O 
21 Detach transmission (15) from crankcase and engine oil pan by removing bolts (21). IMPORTANT First unscrew bolt (21) on the bracket of vent line (22) and remove vent line (23).  
    TORQUE SPECIFICATION *BA27.40-P-1001-01E 
    TORQUE SPECIFICATION *BA27.40-P-1002-01E 
22 Remove transmission (15) from below IMPORTANT Secure torque converter (24) to prevent it from falling out.
IMPORTANTInstallation:  Align threaded holes in the torque converter (24) with the holes in the drive plate.		  
23 Remove torque converter (24) If necessary AR27.20-P-0500-01W 
    Installed height of torque converter *BE27.20-P-1001-01E 
    SPECIAL TOOL Fig 9
    SPECIAL TOOL Fig 8
INSPECT Checking     
24 Check thread in torque converter (24) IMPORTANT Check thread for damage, replace torque converter (24) if damaged.  
25 Install in the reverse order    
26 Fill transmission (15) with transmission oil IMPORTANT Only when replacing the transmission (15) or if the transmission oil has been drained.
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 
27 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 
28 Read out fault memory and erase if necessary STAR DIAGNOSIS diagnostic system  
29 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
30 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
FRAME FLOOR ASSEMBLY

Number Designation Model 251
BA61.10-P-1005-01F Bolt, stiffening bridge to frame floor assembly Nm 20
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
PROPELLER SHAFT

Number Designation Model 251
BA41.10-P-1001-01G Self-locking bolt, propeller shaft to transfer case (to rear axle) Stage 1 Nm 40
Stage 2 ∠° 90
BA41.10-P-1003-01G Self-locking bolt, propeller shaft to transfer case (to front axle) Stage 1 Nm 40
Stage 2 ∠° 90
HOUSING

Number Designation Transmission 722.9 in model 164 Transmission 722.9 in model 251
BA27.40-P-1001-01E Bolt, automatic transmission to crankcase Nm 39 39
BA27.40-P-1002-01E Bolt, automatic transmission to engine oil pan Nm 39 39
BA27.40-P-1003-01E Bolt, heat shield to transmission housing Nm 8 8
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
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
STARTER

Number Designation Engine 156
BA15.30-P-1003-01O Bolt connecting starter to crankcase Nm 40
Fig 4: Identifying Set Of Stop Plugs (129 589 00 91 00)
G05257894Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Identifying Retainer Wrench (164 589 02 07 00)
G05257895Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 6: Identifying Wrench Socket (001 589 65 09 00)
G05257896Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 7: Identifying Long Wedge (115 589 03 59 00)
G05257897Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 8: Identifying Grab Handle (168 589 00 62 00)
G05257898Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 9: Identifying Parallel Support (126 589 04 31 00)
G05257899Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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