Remove/Install Automatic Transmission - AR27.10-P-0502LWH
Transmission 724.2 in model 205 with engine 274.9
MODIFICATION NOTES
| 27.06.2016 | Clamp, front exhaust system to catalytic converter | Engine 274 in model 205 | BA49.10-P-1005-02A |
Fig 1: Automatic Transmission Components Location - Transmission 724.2 In Model 205 With Engine 274.9
| Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC) | Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines. | AS00.00-Z-0035-01A | |
| 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 | |
| Risk of injury caused by scraping or cutting body parts on sharp vehicle parts | Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels. | AS00.00-Z-0017-01A | |
| Risk of injury . Skin or eye injuries may result when handling hot or glowing objects. | Wear protective gloves, protective clothing and safety glasses, if necessary. | AS00.00-Z-0002-01A | |
| General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system | AH00.00-Z-0300-01A | ||
| Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | ||
| Notes on self-locking nuts and bolts | AH00.00-N-0001-01A | ||
| Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | ||
| Notes on battery | AH54.10-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 | Unclip engine air intake duct from front crossmember | ||
| 4 | Perform disable for the high-voltage on-board electrical system | AR54.10-P-1150LW | |
| 5 | Detach ground line of on-board electrical system battery | AR54.10-P-0003LW | |
| 6 | Secure vehicle on vehicle lift | AR00.60-P-0100CW | |
| 7 | Detach high-voltage electrical line (28) from A/C compressor and expose | ||
| 8 | Remove center engine compartment paneling and rear engine compartment paneling | AR61.20-P-1105LW | |
| 9 | Expose high-voltage electrical line (28) downwards | ||
| 10 | Detach ground lines (2) from transmission (1) | *BA27.10-P-1028-04G | |
| 11 | Unlock and separate electrical connector (33) at electrical machine temperature sensor and create access to electrical line | ||
| 12 | Loosen clamp on catalytic converter | *BA49.10-P-1005-02A | |
| 13 | Remove heat shield (3) | AR27.40-P-0700-01LF | |
| 14 | Unlock electrical connector (4) at electrohydraulic controller unit, disconnect and unclip electrical line from transmission (1) | ||
| 15 | Detach oil lines from transmission (1) and oil pan, and set aside | AR27.55-P-0600LWH | |
| 16 | Remove rear engine cross member with rear engine mount | AR22.10-P-4360LWB | |
| Notes on bolted connections with self tapping screws | Never use impact wrench or compressed air tools for screwing in or unscrewing the bolts! Otherwise the threads can get damaged. |
AH00.00-P-0007-01SF | |
| 17 | Lash down transmission (1) | ||
| 18 | Remove screw/bolt (31a) and detach bracket (31) | *BA27.10-P-1027-04G | |
| 19 | Remove bolt (30a) and unclip bracket (30) from transmission (1) | ||
| 20 | Detach drive shaft flexible coupling from the transmission | AR41.10-P-0040-01LW | |
| Drift for releasing the fitted sleeves in the flexible couplings | WF58.50-P-4110-01A | ||
| *BA41.10-P-1001-01L | |||
| Fig 2 | |||
| 21 | Carefully lower transmission (1) slightly | ||
| 22 | Remove bolt (10a) and remove cover (10) | *BA08.10-P-1002-01F | |
| 23 | Remove bolt (11 a) from bracket (11) | *BA27.10-P-1027-04G | |
| 24 | Remove bolts (32a) and hang bracket (32) to one side | *BA08.10-P-1003-01F | |
| 25 | Detach high-voltage plug (29a) of 3-phase high-voltage lines from electrical machine and place at right, next to the transmission (1) | Cover up high voltage plug (29) and handle carefully. Otherwise the high voltage on-board electrical system may be damaged. |
|
| *BA08.10-P-1003-01F | |||
| 26 | Unclip high-voltage electrical line (28) and hang over transmission (1) to right and at one side | ||
| 27 | Detach starter at transmission (1) and hang at one side | Secure starter against falling. Damage will otherwise occur. |
AR15.30-P-7100LWA |
| 28 | Unscrew bolts (1a) and remove transmission (1) from below | ||
| *BA27.10-P-1001-04G | |||
| Anticorrosion grease 40 g/DB supply specification 6834.00 | *BR00.45-Z-1006-06A | ||
| 29 | Install in the reverse order | ||
| 30 | Perform transmission adaptation using diagnostic system | After replacing the transmission (1) or the electrical machine rotor position sensor or the electrical machine | |
| AD00.00-P-2000-04B | |||
| Check | |||
| 31 | Check oil level in transmission (1) and correct | AR27.00-P-0270EH | |
| 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 | |
| 32 | Test run engine and check transmission (1) for leak tightness and proper operation |
ELECTRIC MOTOR
| Number | Designation | Model 205 with code ME05 (Hybrid drive 85 kW-94 kW variant (including plug-in)) | Model 205.0/2 with code ME04 (Mild hybrid drive) | |
|---|---|---|---|---|
| BA08.10-P-1002-01F | Bolt, hoop guard to transmission | Nm | 9 | 15 |
ELECTRIC MOTOR
| Number | Designation | Model 205 with code ME06 (Hybrid drive 60 kW variant (including plug-in)) | |
|---|---|---|---|
| BA08.10-P-1002-01F | Bolt, hoop guard to transmission | Nm | 15 |
ELECTRIC MOTOR
| Number | Designation | Model 205 with code ME05 (Hybrid drive 85 kW-94 kW variant (including plug-in)) | Model 205.0/2 with code ME04 (Mild hybrid drive) | |
|---|---|---|---|---|
| BA08.10-P-1003-01F | Bolt, 3-phase high-voltage line to electrical machine housing | Nm | - | 16 |
ELECTRIC MOTOR
| Number | Designation | Model 205 with code ME06 (Hybrid drive 60 kW variant (including plug-in)) | |
|---|---|---|---|
| BA08.10-P-1003-01F | Bolt, 3-phase high-voltage line to electrical machine housing | Nm | 16 |
AUTOMATIC TRANSMISSION COMPLETE
| Number | Designation | Transmission 724.2 | |
|---|---|---|---|
| BA27.10-P-1001-04G | Bolt/nut, transmission to engine | Nm | 39 |
AUTOMATIC TRANSMISSION COMPLETE
| Number | Designation | Transmission 724.2 | |
|---|---|---|---|
| BA27.10-P-1027-04G | Screw/bolt, bracket for electrical lines to M8 transmission housing | Nm | 20 |
AUTOMATIC TRANSMISSION COMPLETE
| Number | Designation | Transmission 724.2 | |
|---|---|---|---|
| BA27.10-P-1028-04G | Bolt, ground line to transmission housing | Nm | 20 |
PROPELLER SHAFT
| Number | Designation | Model 205 | |||
|---|---|---|---|---|---|
| BA41.10-P-1001-01L | Flex disk or joint flange at transmission/rear axle differential or propeller shaft | Self-locking nut | Nm | 68 | |
| Direct threaded connection | Stage 1 | Nm | 60 | ||
| Stage 2 | ∠° | 90 | |||
EXHAUST SYSTEM
| Number | Designation | Engine 274 in model 205 | |
|---|---|---|---|
| BA49.10-P-1005-02A | Clamp, front exhaust system to catalytic converter/diesel particulate filter | Nm | 22 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1006-06A | Anticorrosion grease 40 g/DB supply specification 6834.00 | A 001 989 37 51 10 |