Remove/Install Transmission With Torque Converter - AR27.10-P-0500LWY
Model 205 with transmission 722.96/97
| 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 | |
| Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil | Wear protective gloves, protective clothing and safety glasses. Do not pour transmission oil into beverage bottles. |
AS00.40-Z-0001-01A | |
| 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 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 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 threaded connections fastened using a tightening angle-based tightening process | AH00.00-P-0020-01A | ||
| Notes on automatic transmission | AH27.19-P-0001-01NKB | ||
| Remove/install | |||
| 1 | Shift transmission (1) into neutral position | ||
| 2 | Release parking brake | ||
| 3 | Disconnect ground line of battery | AR54.10-P-0003LW | |
| 4 | Secure vehicle on vehicle lift | AR00.60-P-0100CW | |
| 5 | Remove center and rear sections of lower engine compartment lining | AR61.20-P-1105LW | |
| 6 | Release and detach electrical connection from intelligent servo module for DIRECT SELECT, and expose electrical line | Model 205 with engine 274 with transmission 722.96 Model 205 with engine 276 with transmission 722.96 Model 205 with engine 276 with transmission 722.97 |
AR27.19-P-0550LWA |
| Model 205 with engine 651 with transmission 722.96 |
AR27.19-P-0550LWB | ||
| 7.1 | Remove SCR catalytic converter | Model 205 with engine 651 with transmission 722.96 Exhaust system |
AR49.10-P-7100LWB |
| 7.2 | Center exhaust system | Model 205 with engine 274 with transmission 722.96 Model 205 with engine 276 with transmission 722.96/97 |
AR49.10-P-7283LW |
| 8 | Remove front axle differential propeller shaft from front axle differential | AR41.10-P-0070LWY | |
| 9 | Remove bracket of left catalytic converter | Model 205 with engine 276 with transmission 722.96/97 | AR49.10-P-5502MMV |
| 10 | Disconnect ground line (2) from transmission (1) | ||
| 11 | Remove heat shield (4) from transmission (1) | ||
| 12 | Unlock and disconnect electrical connector from electric controller unit and detach electrical line from transmission (1) and place to one side | ||
| 13 | Release, detach electrical connector from electrical auxiliary oil pump (3) and detach electrical line from transmission (1) and place to one side | ||
| 14 | Remove torque converter (10) from drive plate and pry off drive plate uniformly using long wedge | AR27.20-P-0100-01A | |
| *BA27.20-P-1002-01C | |||
| Fig 7 | |||
| Fig 4 | |||
| 15 | Support and lash down transmission (1) | ||
| 000 588 10 62 00 Support plate | WS26.00-P-3309B | ||
| 000 588 11 62 00 Major assembly mount | WS01.00-P-0092B | ||
| 16 | Remove engine cross member at rear | Never use impact wrenches/drivers or compressed air tools for screwing the bolts in and out! Otherwise, the threads may be damaged. |
AR22.10-P-4360LWB |
| 17 | Detach flex disk of propeller shaft at transmission end | AR41.10-P-0040-01LW | |
| Drift for releasing the fitting sleeves in the flexible couplings | WF58.50-P-4110-01A | ||
| *BA41.10-P-1001-01L | |||
| Fig 5 | |||
| 18 | Remove oil lines from transmission (1) and oil pan and place to one side | AR27.55-P-0600LWY | |
| 19 | Remove starter from transmission (1) and secure against falling down | Model 205 with engine 274 with transmission 722.96 | AR15.30-P-7100LWA |
| Model 205 with engine 276 with transmission 722.96 Model 205 with engine 276 with transmission 722.97 |
AR15.30-P-7100MMV | ||
| Model 205 (except 205.012/212) with engine 651 with transmission 722.96 | AR15.30-P-7100LWB | ||
| 20 | Unscrew bolts (1a) and remove transmission (1) downwards | Secure the torque converter (10) to prevent it from dropping down. Damage will otherwise occur. |
*BA27.40-P-1008-01A |
| 21 | Remove torque converter (10) using grab handles | If necessary. | AR27.20-P-0500-01W |
| Multi-purpose paste | *BR00.45-Z-1009-06A | ||
| Installed height of torque converter | *BE27.20-P-1001-01E | ||
| Fig 6 | |||
| Fig 3 | |||
| Clean | |||
| 22 | Remove corrosion from crankshaft | AR03.20-P-1000-01A | |
| Multi-purpose paste | *BR00.45-Z-1009-06A | ||
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Check | |||
| 23 | Check threaded unions in drive plate | If threaded unions are damaged or loosened ↓ replace drive plate. Model 205 with engine 274 with transmission 722.96 |
AR03.30-P-8001MRA |
| Model 205 with engine 276 with transmission 722.96 | AR03.30-P-8001MMV | ||
| Model 205 with engine 651 with transmission 722.96 | AR03.30-P-8001OLD | ||
| 24 | Install in the reverse order | ||
| 25 | Check and correct transmission oil level | AR27.00-P-0270SYZ | |
| 26 | Read out and erase fault memory | ||
| AD00.00-P-2000-04B | |||
| 27 | Perform transmission adaptation using diagnostic system | After replacement or repair of transmission (1). | |
| AD00.00-P-2000-04B | |||
| 28 | Reset data on service life of torque converter lockup clutch using diagnostic system | After replacement or repair of torque converter (10). | |
| AD00.00-P-2000-04B | |||
| 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 | |
| 29 | Perform engine test run and check transmission (1) for proper operation and leak tightness | ||
| 30 | Install center and rear sections of lower engine compartment lining | AR61.20-P-1105LW | |
| 31 | Disconnect vehicle from vehicle lift | AR00.60-P-0100CW |
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 |
| See picture | AR27.20-P-0500-01W | ||||
| Axial screwed connection | mm | 19, 5 | |||
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 | - | ||
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 | |||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1009-06A | Multi-purpose paste | A 000 989 80 51 |
| BR00.45-Z-1028-04A | Assembly cleaner | A 000 986 56 01 |