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

TRANSMISSION 722.9 (except 722.96) in MODEL 207

TRANSMISSION 722.9 (except 722.96/997) in MODEL 204

MODIFICATION NOTES

5.3.14

"Remove corrosion from crankshaft" added.

Step 28

Fig 1: Identifying Transmission With Torque Converter Remove/Install Components (1 Of 2)

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Notes on automatic transmission		AH27.19-P-0001-01NKB
	Remove/install
1	Move selector lever into position "N"
2	Release parking brake
3	Detach ground line from battery	MODEL 204 with TRANSMISSION 722.9 (except 722.96/997)	AR54.10-P-0003CW
	Notes on battery	MODEL 204 with TRANSMISSION 722.9 (except 722.96/997)	AH54.10-P-0001-01A
	Notes on battery	MODEL 207 with TRANSMISSION 722.9 (except 722.96)	AR54.10-P-0003EW
4	Secure vehicle on vehicle lift		AR00.60-P-0100CW
5.1	Remove engine compartment paneling	With gasoline engines
		MODEL 204.9 with TRANSMISSION 722.9 (except 722.96/997)	AR61.20-P-1105CY
		MODEL 204.0/2/3, 207	AR61.20-P-1105EW
5.2	Remove bottom sections of soundproofing	On diesel engines
5.2	Remove bottom sections of soundproofing	MODEL 204.0/2/3, 207	AR94.30-P-5300EW
5.3	Remove both lower engine compartment paneling	MODEL 204.9
5.3	Remove both lower engine compartment paneling	MODEL 204.9	AR61.20-P-1105CY
6	Remove air duct housing	TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 272.982 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 272.982
6	Remove air duct housing		AR09.20-P-0080CV
7	Disconnect electrical connectors of heated oxygen sensor and unclip from bracket	TRANSMISSION 722.9 (except 722.96) in MODEL 207 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204.0/2/3 Except TRANSMISSION 722.9 (except 722.96) in MODEL 204.9 with ENGINE 274 TRANSMISSION 722.9 (except 722.96) in MODEL 207
		TRANSMISSION 722.9 (except 722.96/997) in MODEL 204.0/2/3	AR07.52-P-5303FH
		TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 278	AR07.52-P-5303ELB
		TRANSMISSION 722.9 (except 722.96) in MODEL 204 with ENGINE 156	AR07.52-P-5303CMG
		TRANSMISSION 722.9 (except 722.96) in MODEL 204 (except 204.05/06/25/95) with ENGINE 272 TRANSMISSION 722.9 (except 722.96/995) in MODEL 207 with ENGINE 272 TRANSMISSION 722.9 (except 722.96/995) in MODEL 207 with ENGINE 273	AR07.52-P-5303CV
8.1	Detach bracket of diesel particulate filter between diesel particulate filter and transmission (5)	TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 642 TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 651 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 642 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 651
		Bolt, automatic transmission to engine	*BA27.40-P-1008-01A
		TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 642 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 651	*BA49.10-P-1002-01AC
		TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 642 TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 651	*BA49.10-P-1009-01AE
8.2	Remove catalytic converter bracket at transmission (5)	TRANSMISSION 722.9 (except 722.96/995) in MODEL 207 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204
		MODEL 204 (except 204.9) with ENGINE 274 with TRANSMISSION 722.9 (except 722.96)	AR49.10-P-7100MR
		TRANSMISSION 722.9 (except 722.96/995) in MODEL 207 with ENGINE 271 TRANSMISSION 722.9 (except 722.96/995) in MODEL 207 with ENGINE 272 TRANSMISSION 722.9 (except 722.96/995) in MODEL 207 with ENGINE 273 TRANSMISSION 722.9 (except 722.96/995) in MODEL 207 with ENGINE 276 TRANSMISSION 722.9 (except 722.96/995) in MODEL 207 with ENGINE 278 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 156 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 272 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 276	AR49.10-P-7100CW
8.3	Remove catalytic converters	TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 278
8.3	Remove catalytic converters		AR49.10-P-7100CW
9	Remove heat shield (1) and disconnect electrical connector from electric controller unit		AR27.40-P-0700-01CW
9		Bolt, heat shield to transmission housing	*BA27.40-P-1014-01A
10	Disconnect electrical connector from electric oil pump and unclip electrical line from transmission (5)	If installed
11	Release and disconnect electrical connector from intelligent servo module	TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 276.8 TRANSMISSION 722.994/995 in MODEL 207 with ENGINE 274 TRANSMISSION 722.995 in MODEL 204.9 with ENGINE 274
11		TRANSMISSION 722.994/995 in MODEL 207 with ENGINE 274	AR27.19-P-0550ECM
12	Detach ground line (2) to transmission (5)	ENGINE 156 The bracket for the oxygen sensor electrical connector is secured to the transmission (5) by means of the screw/bolt of the ground line (2).
		Bolt, automatic transmission to engine	*BA27.40-P-1008-01A
		Bolt, ground strap to transmission	*BA15.10-P-1002-05C
13	Remove exhaust system bracket (4)	TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 274	AR49.10-P-7100ECM
		TRANSMISSION 722.90 in MODEL 204 with ENGINE 272 TRANSMISSION 722.90 in MODEL 207 with ENGINE 272	AR49.10-P-7100CW
		ENGINE 642, 651	AR49.10-P-7100CWI
14.1	Remove pipe clamp securing diesel particulate filter to pipe	TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 642 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 642
14.1			AR49.10-P-7100CWI
14.2	Remove diesel particulate filter	TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 651 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204.0/2/3 with ENGINE 651
14.2	Remove diesel particulate filter		AR49.10-P-5501CD
14.3	Detach left and right catalytic converter from front exhaust pipes	TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 276.8
14.3			AR49.10-P-7100CW
14.4	Detach exhaust system from exhaust manifolds	MODEL 204 with ENGINE 156 with TRANSMISSION 722.90 without CODE P98 (Black Series) MODEL 204 with ENGINE 156 with TRANSMISSION 722.93 without CODE P98 (Black Series) MODEL 204, 207 with ENGINE 272.982 with TRANSMISSION 722.90 without CODE P98 (Black Series)
14.4	Detach exhaust system from exhaust manifolds		AR49.10-P-7100CW
14.5	Detach exhaust system from catalytic converter	TRANSMISSION 722.9 (except 722.96) in MODEL 204 (except 204.9) with ENGINE 274 TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 274
		TRANSMISSION 722.9 (except 722.96) in MODEL 204 (except 204.9) with ENGINE 274	AR49.10-P-7100MR
		MODEL 207 with ENGINE 274 with TRANSMISSION 722.9 (except 722.96) Protect the decoupling element using the assembly tool. The decoupling element will otherwise be damaged. Replace clamp if necessary.	AR49.10-P-7100ECM
15	Remove left exhaust line	Engine 272.982
		Engine 272.982	AR14.20-P-1020-01CDE
		MODEL 204, 207	*BA27.40-P-1008-01A
		MODEL 204	*BA49.10-P-1031-01AC
		MODEL 204	*BA49.10-P-1032-01AC
		MODEL 207	*BA49.10-P-1040-01AE
		MODEL 207	*BA49.10-P-1041-01AE
16	Support and lash down transmission (5)	Transmission jack Transmission platform
17	Remove rear engine crossmember (7a) with rear engine mount (7b)	TRANSMISSION 722.9 (except 722.96) in MODEL 207 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 272 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 274 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 276 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 642 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 651	AR22.10-P-1180CW
	Notes on bolted connections with self tapping screws		AH00.00-P-0007-01SF
	Notes on bolted connections with self tapping screws	TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 156	AR22.10-P-1180CMG
18	Mark propeller shaft	Attach color marking to identify the propeller shaft position at the flange of the transmission (5), in order to find the original factory installation position when reinstalling.
19.1	Remove front flexible coupling (20v)	MODEL 204, 207 with TRANSMISSION 722.9 (except 722.96/995/997)
19.1	Remove front flexible coupling (20v)		AR41.10-P-0050CW
19.2	Detach front flexible coupling (20v) from transmission output flange	TRANSMISSION 722.994/995 in MODEL 207 with ENGINE 274
19.2		TRANSMISSION 722.994/995 in MODEL 207 with ENGINE 274	AR41.10-P-0050CW
20	Detach shift rod (15) at range selector lever (16) of transmission (5)	TRANSMISSION 722.9 (except 722.904/96/995/997) in MODEL 207 TRANSMISSION 722.9 (except 722.96/995/997) in MODEL 204 Replace retaining clamp (14a).
21	Detach torque converter or start-up clutch (9) from driver spider and pry off from driver spider uniformly using long wedge	TRANSMISSION 722.9 (except 722.93/96/997) in MODEL 204 TRANSMISSION 722.9 (except 722.96) in MODEL 207	AR27.20-P-0100-01A
		TRANSMISSION 722.93 in MODEL 204 Do not use impact wrenches or compressed air tools. The threaded unions in the driver spider will otherwise be damaged. TRANSMISSION 722.9 (except 722.96/997) in MODEL 204, 207with angled threaded connection Installation: Replace screw/bolts.	AR27.51-P-0400-01W
		TRANSMISSION 722.90, 722.99 (except 722.997) in MODEL 204, 207	*BA27.20-P-1002-01C
		TRANSMISSION 722.93 in MODEL 204	*BA27.51-P-1001-01A
		Socket wrench bit	Fig 6
		Long wedge	Fig 3
22	Detach oil lines from transmission (5) and oil pan and place to one side	TRANSMISSION 722.9 (except 722.96/995/997) in MODEL 204 (except 204.077/277/377) TRANSMISSION 722.995 in MODEL 204.9 with ENGINE 274	AR27.55-P-0600CV
		TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 156	AR27.55-P-0600CMG
		TRANSMISSION 722.995 in MODEL 204 (except 204.9) with ENGINE 274 TRANSMISSION 722.995 in MODEL 207 with ENGINE 274.9	AR27.55-P-0600MR
		TRANSMISSION 722.9 (except 722.96/995) in MODEL 207 Before starting work the area around the oil 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). TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 276.8 Also detach the oil lines from the refrigerant compressor. Do not kink or bend the oil lines. Seal off the connections on the transmission (5) and the oil lines using stop plugs.	AR27.55-P-0600EV
		Record plug	Fig 7
23	Detach starter from transmission (5)	TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 156	AR15.30-P-7100CMG
		TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 271	AR15.30-P-7100CW
		TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 272 TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 273 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 272	AR15.30-P-7100CV
		TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 274 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 274	AR15.30-P-7100MR
		TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 276 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 276	AR15.30-P-7100FH
		TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 278	AR15.30-P-7100ELB
		TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 642	AR15.30-P-7100CO
		TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 642	AR15.30-P-7100SXI
		TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 651 TRANSMISSION 722.9 (except 722.96/997) in MODEL 204 with ENGINE 651 Place starter to the side with lines connected and secure to prevent it falling down.	AR15.30-P-7100CD
24	Detach bracket (12) from transmission (5); to do so, screws/remove bolts (12a)	TRANSMISSION 722.9 (except 722.96) in MODEL 207 with ENGINE 276.8
24		Bracket, wiring harness to automatic transmission	*BA27.40-P-1024-01A
25	Support engine at the oil pan	ENGINE 156 When the transmission (5) is removed, the engine must be propped up at the oil pan in order to prevent the engine from tipping over.
26	Remove bolts (8) and remove transmission (5) downwards	Secure the torque converter or start-up clutch (9) to prevent them from falling out. The torque converter or start-up clutch (9) can otherwise be damaged. Align the bores of the torque converter or start-up clutch (9) with the threaded unions in the driver spider.
26	Remove bolts (8) and remove transmission (5) downwards	Bolt, automatic transmission to engine	*BA27.40-P-1008-01A
27	Remove torque converter or start-up clutch (9) using grab handles	If necessary
		TRANSMISSION 722.9 (except 722.93/96/997) in MODEL 204 TRANSMISSION 722.9 (except 722.96) in MODEL 207	AR27.20-P-0500-01W
		TRANSMISSION 722.93 in MODEL 204	AR27.51-P-0400-02AMG
		TRANSMISSION 722.9 (except 722.93)	*BE27.20-P-1001-01E
		TRANSMISSION 722.93 in MODEL 204	*BE27.51-P-1001-02A
		Multi-purpose paste	*BR00.45-Z-1009-06A
		Handles	Fig 5
		Parallel rest	Fig 4
28	Remove corrosion from crankshaft		AR03.20-P-1000-01A
		Assembly cleaner	*BR00.45-Z-1028-04A
		Multi-purpose paste	*BR00.45-Z-1009-06A
	Check
29	Check threaded unions in driver spider	If threaded unions are damaged or loose ↓ Install a new driver spider.
		MODEL 207 with ENGINE 642 with TRANSMISSION 722.9 (except 722.96)	AR03.30-P-8001SXI
		MODEL 204 with ENGINE 274 with TRANSMISSION 722.9 (except 722.96/997) MODEL 207 with ENGINE 274 with TRANSMISSION 722.9 (except 722.96)	AR03.30-P-8001MR
		MODEL 204 with ENGINE 276 with TRANSMISSION 722.9 (except 722.96/997) MODEL 207 with ENGINE 276 with TRANSMISSION 722.9 (except 722.96) MODEL 207 with ENGINE 278 with TRANSMISSION 722.9 (except 722.96)	AR03.30-P-8001FH
		MODEL 207 with ENGINE 271 with TRANSMISSION 722.9 (except 722.96)	AR03.30-P-8001CW
		MODEL 204 with ENGINE 272 with TRANSMISSION 722.9 (except 722.96/997) MODEL 207 with ENGINE 272 with TRANSMISSION 722.9 (except 722.96) MODEL 207 with ENGINE 273 with TRANSMISSION 722.9 (except 722.96)	AR03.30-P-8001CV
		MODEL 204 with ENGINE 642 with TRANSMISSION 722.9 (except 722.96/997)	AR03.30-P-8001CO
		MODEL 204 with ENGINE 156 with TRANSMISSION 722.9 (except 722.96/997)	AR03.30-P-8001CMG
		MODEL 204 with ENGINE 651 with TRANSMISSION 722.9 (except 722.96/997) MODEL 207 with ENGINE 651 with TRANSMISSION 722.9 (except 722.96)	AR03.30-P-8001CD
30	Install in the reverse order
31	Fill transmission (5) with transmission oil	After replacing the transmission (5) or if transmission oil has been drained off.
31	Fill transmission (5) with transmission oil		AR27.00-P-0270W
32	Check transmission oil level and correct if necessary		AR27.00-P-0270W
33	Read out fault memory using the diagnostic system and clear if necessary
			AD00.00-P-2000-04A
34	Perform transmission adaptation using diagnostic system	After replacement or repair of transmission (5)
35	Reset data on service life of torque converter lockup clutch using diagnostic system	After replacing torque converter (9)
	Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off 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

TEST VALUES FOR TORQUE CONVERTER

Number	Designation				TRANSMISSION 722.9
BE27.20-P-1001-01E	Installed height of torque converter	Distance, bolt flange to transmission housing flange	Helical screwed connection	mm	9, 5
					AR27.20-P-0500-01W
			Axial screwed connection	mm	19, 5

TEST VALUES FOR START UP CLUTCH

Number	Designation			TRANSMISSION 722.93
BE27.51-P-1001-02A	Installed height of start up clutch	Distance, bolt flange to transmission housing flange	mm	9, 5
BE27.51-P-1001-02A	Installed height of start up clutch			-

GROUND STRAP

Number	Designation			MODEL 204	MODEL 207
BA15.10-P-1002-05C	Bolt, ground strap to transmission	M8	Nm	27	16
BA15.10-P-1002-05C	Bolt, ground strap to transmission	M10	Nm	-	-

TORQUE CONVERTER

Number	Designation				TRANSMISSION 722.9
BA27.20-P-1002-01C	Bolt, torque converter to driver spider	Straight threaded connection	M8	Nm	42
		Angled threaded connection	Stage 1	Nm	4
			Stage 2	Nm	30
			Stage 3	∠°	90

HOUSING

Number	Designation			TRANSMISSION 722.9
BA27.40-P-1008-01A	Bolt, automatic transmission to engine	M10X40	Nm	38
		M10X45	Nm	38
		M10X90	Nm	38
		M12	Nm	-

HOUSING

Number	Designation		TRANSMISSION 722.9
BA27.40-P-1014-01A	Bolt, heat shield to transmission housing	Nm	9

HOUSING

Number	Designation		TRANSMISSION 722.9
BA27.40-P-1024-01A	Bracket, wiring harness to automatic transmission	Nm	10

START UP CLUTCH

Number	Designation			TRANSMISSION 722.93
BA27.51-P-1001-01A	Bolt, start up clutch to driver	Stage 1	Nm	4
		Stage 2	Nm	30
		Stage 3	∠°	90

EXHAUST SYSTEM

Number	Designation		ENGINE 642, 646, 651 in MODEL 204
BA49.10-P-1002-01AC	Bolt connecting catalytic converter to turbocharger	Nm	20

EXHAUST SYSTEM

Number	Designation		ENGINE 642, 651 in MODEL 207
BA49.10-P-1009-01AE	Bolt/nut, bracket of diesel particulate filter to lower diesel particulate filter	Nm	20

EXHAUST SYSTEM

Number	Designation		ENGINE 156, 271, 272 in MODEL 204
BA49.10-P-1031-01AC	Bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner	Nm	9

EXHAUST SYSTEM

Number	Designation		ENGINE 156, 271, 272 in MODEL 204
BA49.10-P-1032-01AC	Bolt, exhaust gas recirculation line clamp to catalytic converter	Nm	9

EXHAUST SYSTEM

Number	Designation		ENGINE 271, 272, 273, 276, 278 in MODEL 207
BA49.10-P-1040-01AE	Bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner	Nm	9

EXHAUST SYSTEM

Number	Designation		ENGINE 271, 272, 273, 276, 278 in MODEL 207
BA49.10-P-1041-01AE	Bolt, clamp for exhaust gas recirculation line to catalytic converter	Nm	9

Fig 3: Identifying Long Wedge (115 589 03 59 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Parallel Rest (126 589 04 31 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Handles (168 589 00 62 00)

Courtesy of MERCEDES-BENZ USA

Fig 6: Identifying Socket Wrench Bit (001 589 65 09 00)

Courtesy of MERCEDES-BENZ USA

Fig 7: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1009-06A	Multi-purpose paste	A 000 989 80 51 10
BR00.45-Z-1028-04A	Assembly cleaner	Adolf Wurth GmbH & Co. KG