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

TRANSMISSION 722.96 in MODEL 204.0/2/9 with 4MATIC 

TRANSMISSION 722.96 in MODEL 212, 218 

Fig 1: Identifying Transmission, Screw And Torque Converter

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 204 with diesel engine 

Fig 2: Identifying Transmission With Torque Converter Remove/Install Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove/install
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
		Before starting work the area around the oil cooler lines must be thoroughly cleaned in the area around the separation points on the transmission (5). Even the smallest dirt particles in the hydraulic components can lead to malfunctions and a total failure of the transmission (5).
1	Move selector lever into position "N"
2	Release parking brake
3	Detach ground line from battery	Model 204	AR54.10-P-0003CW
		Model 212, 218	AR54.10-P-0003EW
	Notes on battery		AH54.10-P-0001-01A
4	Secure vehicle on vehicle lift	Model 204	AR00.60-P-0100CW
		Model 212, 218	AR00.60-P-0100EWS
5.1	Remove catalytic converters	Model 204 with engine 272, 276	AR49.10-P-7100CW
5.2	Remove catalytic converters with front connecting strut	Model 212 with engine 272, 273	AR49.10-P-7100EW
5.3	Remove catalytic converters together with center muffler	Model 212 with engine 276, 278 Model 218 with engine 278	AR49.10-P-7100EL
5.4	Remove catalytic converter	Model 204 with engine 642 up to model year 2009	AR49.10-P-5500CO
		Model 212 with engine 651	AR49.10-P-5500OMD
5.5	Remove diesel particulate filter	Model 204 with engine 642 as of model year 2009	AR14.40-P-1000CWI
5.6	Remove catalytic converter diesel particulate filter unit	Model 204 with engine 651
6.1	Detach front exhaust bracket (17) between engine and transmission (5)	Model 204 with engine 272, model 212 with engine 651 Engine 272 in model 204:
			*BA49.10-P-1008-01AC
		Engine 651 in model 212:	*BA49.10-P-1010-01AC
			*BA49.10-P-1023-01AE
			*BA49.10-P-1025-01AE
6.2	Detach front exhaust bracket (17) and rear exhaust bracket on transmission (5)	Model 204, 212 with engine 642, 651 Model 204:	*BA49.10-P-1002-01AC
			*BA49.10-P-1009-01AC
		Model 212:	*BA49.10-P-1011-01AC
			*BA49.10-P-1002-01AE
			*BA49.10-P-1024-01AE
			*BA49.10-P-1026-01AE
6.3	Remove exhaust bracket from transmission (5)	Model 204 with engine 276	*BA49.10-P-1035-01AC
			*BA49.10-P-1036-01AC
7	Mark position of front flexible coupling (20v) relative to transmission (5)	In order when installing to be able to reproduce the installation position used by the plant. Otherwise, drive train vibrations will occur.
8	Detach front flexible coupling (20v) on transmission (5)	The front flexible coupling (20v) remains on the propeller shaft (20). Model 204	AR41.10-P-0050CW
		Model 212, 218	AR41.10-P-0050EW
9	Remove shield and disconnect electrical connector on electric controller unit	Model 204	AR27.40-P-0700-01CW
			*BA27.40-P-1003-01E
		Model 212, 218	AR27.40-P-0700-01EW
			*BA27.40-P-1003-01E
10	Detach ground line (49) from transmission (5)
11	Support transmission (5) and secure to prevent it from falling down	Transmission jack 2.0-7.0 t	Transmission platform for passenger cars and commercial vehicles
12	Remove rear engine cross member (2)		AR22.10-P-1180CW
	Notes on bolted connections with self tapping screws		AH00.00-P-0007-01SF
13.1	Detach shift rod at range selector lever of transmission (5)	Installation  : Replace retaining clamp. Except model 212, 218
13.2	Detach electrical line from intelligent servo module for DIRECT SELECT	Model 212, 218
14	Disconnect electrical line from transmission oil pump, unclip from transmission (5) and place outside of the working area	If an auxiliary oil pump is installed.
15	Detach front axle transmission drive shaft and fasten to transmission (5) using tensioning strap	Model 204	AR41.10-P-0070CWX
		Model 212, 218	AR41.10-P-0070EWX
16	Remove oil drain screw from transmission oil pan and drain automatic transmission fluid	Only when replacing the transmission (5) or the torque converter (9) Installation  : Install new sealing ring. If the transmission oil is burnt or interspersed with abrasion, the oil cooler lines and oil cooler must be flushed out. Otherwise the transmission (5) may be damaged: ↓
		Flush out oil cooler lines and oil cooler.	AR27.55-P-0100B
			*BA27.10-P-1001-03D
17	Detach bracket of wiring harness on transmission (5)	Engine 272, 651
18	Detach oil cooling lines from transmission (5), transfer case and engine oil pan and place to one side		AR27.55-P-0600CWX
19	Detach torque converter (9) from driven plate and pry driven plate (7) off evenly using a long wedge	Do not use an impact wrench/driver or a compressed-air tool. Otherwise the threaded unions (7a) of the driven plate (7) may be damaged.	AR27.20-P-0100-01A
			*BA27.20-P-1002-01C
		Socket wrench bit	Fig 3
		Long wedge	Fig 4
20	Detach starter from transmission (5)	Place starter to the side with lines connected and secure to prevent it falling down. Engine 642 in model 204.08/28/98	AR15.30-P-7100CWX
		Engine 642 in model 212	AR15.30-P-7100SXI
		Engine 272, 273 in model 212	AR15.30-P-7100EW
		Engine 651	AR15.30-P-7100CD
		Engine 272 in model 204	AR15.30-P-7100CV
		Engine 276 in model 204	AR15.30-P-7100FH
		Engine 276 in model 212	AR15.30-P-7100EL
		Engine 278 in model 212, 218	AR15.30-P-7100ELB
21	Remove bolts (8)	Installation  : Secure bracket of electric feed lines at transmission (5).
			*BA27.40-P-1001-01E
			*BA27.40-P-1002-01E
22	Remove transmission (5) from below	Secure torque converter (9) to prevent it from falling out.
		Installation  : Align the holes of the torque converter (9) with the threaded unions (7a) in the driven plate (7).
23	Remove torque converter (9)	If necessary.	AR27.20-P-0500-01W
		Installed height of torque converter	*BE27.20-P-1001-01E
		Parallel support	Fig 5
		Handle	Fig 6
		Multipurpose paste	*BR00.45-Z-1009-06A
	Checking
24	Check threaded unions (7a) of driven plate (7)	The driven plate (7) must be replaced if the threaded unions (7a) are damaged or loose.
25	Check rear engine mount for wear and damage	If necessary replace rear engine mount: ↓
		Remove/install engine mount or rear engine crossmember.	AR22.10-P-1180CW
26	Install in the reverse order
27	Fill transmission (5) with transmission oil	When replacing the transmission (5) or if the transmission oil has been drained	AR27.00-P-0270SYZ
28	Check and correct transmission oil level		AR27.00-P-0270SYZ
29	Read out fault memory with STAR DIAGNOSIS and erase if necessary Connect STAR DIAGNOSIS Read out fault memory		AD00.00-P-2000-04A
30	Perform transmission adaptation	A transmission adaptation must be carried out after exchanging or repairing the transmission (5).
	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	Test run engine and check transfer case and transmission (5) for leaks and function

Fig 3: Identifying Wrench Socket (001 589 65 09 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.