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

TRANSMISSION 722.6 in MODEL 221.1, 216.3

Fig 1: Identifying Torque Converter Transmission Remove/Install Components (1 Of 3)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Torque Converter Transmission Remove/Install Components (2 Of 3)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Torque Converter Transmission Remove/Install Components (3 Of 3)

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

6.8.08	Value changed: Filling capacity, Specification		*BF27.00-P-1001-01C
	Value changed: Filling capacity, Specification		*BF27.00-P-1001-01C

	Remove/install
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Before starting work, the area around the oil cooling lines (10L, 10R) must be thoroughly cleaned at 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 DIRECT SELECT gear selector switch to position "N"
2	Release parking brake
3	Open engine hood
4	Disconnect ground lines from batteries		AR54.10-P-0003SX
5	Secure vehicle on vehicle lift		AR00.60-P-0100SX
6	Remove lower engine compartment paneling	Vehicles without code (Z07) Top protection	AR61.20-P-1105SX
6	Remove lower engine compartment paneling	Vehicles with code (Z07) Top protection	AR61.20-P-1105SXS
7	Remove front exhaust bracket (17) from transmission (5)		*BA49.10-P-1008-01Z
8	Remove catalytic converters	See: Remove components of exhaust system.	AR49.10-P-7100SX
9	Remove shield (1) and disconnect electrical connector from electric controller unit		AR27.40-P-0700-01SX
10	Unclip electrical feed lines from bracket (6) on transmission (5) and place to one side
11	Remove bolts securing bracket (6) to transmission (5)		*BA27.40-P-1014-01A
12	Disconnect electrical connector (12) on intelligent servo module (A80)
13	Remove oil drain screws from transmission oil pan and torque converter (7) and drain transmission oil	If necessary If there are metal shavings in the transmission oil pan, allow the transmission oil to drain out of the torque converter (7) through a clean cloth If there are metal shavings in the cloth after draining the transmission fluid, the torque converter (7) must be replaced. If the transmission oil is burnt or contains wear debris, the oil cooling lines (10L, 10R) and oil cooler must be flushed out, otherwise damage could be caused inside the transmission (5): ↓
		Flush out oil cooling lines (10L, 10R) and oil cooler. Only flush out the torque converter (7) with transmission oil.	AR27.55-P-0001A
			*BA27.10-P-1001-03A
			*BA27.20-P-1001-01C
			*BF27.00-P-1001-01C
14	Detach heat shield and starter from transmission (5)	Place starter to the side with lines connected and secure to prevent it falling down.	AR15.30-P-7100SZ
15	Detach left heat shield from transmission (5)
16	Detach torque converter (7) from driven plate; to do so, unclip cover (13) from engine oil pan and remove bolts (7a)	Crank the engine at the center bolt of the crankshaft in the direction of engine rotation until the bolts (7a) are accessible through the recess in the engine oil pan.
16			*BA27.20-P-1002-01C
17	Pry torque converter (7) evenly off driven plate using long wedge		Figure
18	Detach oil cooling lines (10L, 10R) from transmission (5); to do so, remove banjo bolts (15)	Replace sealing rings.
18			*BA27.55-P-1002-01B
19	Detach oil cooling lines (10L, 10R) from brackets; to do so, remove bolts (11)	Do not bend or kink the oil cooling lines (10L, 10R).	AR27.55-P-0600SX
20	Detach bracket (6) of electrical connectors from transmission (5)
21	Support transmission (5) with transmission jack and platform	Secure the transmission (5) with a tensioning strap to prevent it from tilting and slipping off. Transmission jack 2.0-7.0 t Transmission plate for passenger cars and commercial vehicles
22	Remove rear engine crossmember (3) and detach rear engine mount (2) from transmission (5); to do this, unscrew bolts (4, 9)		AR22.10-P-1180SX
23	Mark position of front flexible coupling (20V) relative to transmission (5) and to propeller shaft (20)	This is to ensure reinstallation at the ex-factory installation position, otherwise drive line vibrations can be produced.
24	Remove front flexible coupling (20V)	If the fitted sleeves are jammed: ↓	AR41.10-P-0050-02SX
		Loosen fitted sleeves in front flexible coupling (20V).	AR41.10-P-0050-09SX
		Attach the front flexible coupling (20V) to the transmission (5).	AR41.10-P-0050-07SX
25	Remove oil filler pipe of transmission (5)		AR27.10-P-7010SZ
26	Remove bolts (8)	Secure the bracket of the electrical feed lines and the catalytic converter bracket to the transmission (5).
			*BA49.10-P-1011-01Z
			*BA27.40-P-1008-01A
27	Remove transmission (5) from below	Secure torque converter (7) to prevent it from falling out. Align the bolt holes on the torque converter (7) with the holes in the driven plate.
28	Remove torque converter (7) with grab handles	If necessary	AR27.20-P-0500-01P
	Checking
29	Check threaded unions in torque converter (7)	A new torque converter (7) must be installed if the threaded unions are damaged.
30	Check rear engine mount (2) for wear and damage; replace if necessary
31	Check front flexible coupling (20V) for wear and damage
	Check propeller shaft flex disks for signs of damage and deformation		AP41.10-P-4152SX
32	Install in the reverse order
33	Check oil level in automatic transmission (5); correct if necessary		AR27.00-P-0100AC
34	Read out fault memory with STAR DIAGNOSIS and erase if necessary
35	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
36	Perform engine test run and check transmission (5) for function and leaks		AS00.00-Z-0005-01A

TORQUE CONVERTER

Number	Designation				Transmission 722.6 except 722.648
BA27.20-P-1001-01C	Oil drain bolt to torque converter		M8	Nm	10
BA27.20-P-1001-01C	Oil drain bolt to torque converter		M10	Nm	15
BA27.20-P-1002-01C	Bolt, torque converter to drive plate	Straight threaded connection	M8	Nm	42
		Angled threaded connection	Stage 1	Nm	4
			Stage 2	Nm	30
			Stage 3	∠	90

HOUSING

Number	Designation			Transmission 722.6 except 722.660/661/662/663/666/673/674
BA27.40-P-1008-01A	Bolt, automatic transmission to engine	M10 X 40	Nm	39
		M10 X 90	Nm	39
		M12	Nm	-
BA27.40-P-1014-01A	Bolt, heat shield to transmission housing		Nm	11

EXHAUST SYSTEM

Number	Designation		Engine 275 in model 216	Engine 275 in model 221
BA49.10-P-1008-01Z	Bolt, catalytic converter bracket to transmission	Nm	20	20
BA49.10-P-1011-01Z	Bolt, catalytic converter bracket to top bracket/transmission housing	Nm	20	20

OIL PAN, AUTOMATIC TRANSMISSION

Number	Designation		Transmission 722.649
BA27.10-P-1001-03A	Oil drain screw to oil pan	Nm	22

TRANSMISSION OIL COOLING

Number	Designation			Transmission 722.6 in model 204, 216, 221
BA27.55-P-1002-01B	Banjo bolt or union nut, oil cooler line to torque converter and transmission housing	Stage 1	Nm	5
		Stage	2 ∠	90
		Hexalobular bolt	Nm	12

AUTOMATIC TRANSMISSION

Number	Designation			Transmission 722.649
BF27.00-P-1001-01C	Filling capacity	Initial charge	Liters	8, 0
		during oil change	Liters	6.5
		Specifications for Operating Fluids	Specification	Automatic transmission fluids (ATF, Specification 236.14). See https://bevo.mercedes-benz.com/index.php?language_id=1
		Specifications for Operating Fluids	Specification	-

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

Courtesy of MERCEDES-BENZ USA