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

TRANSMISSION 722.9 in MODEL 166 

Shown on engine 276.9 with CODE 920 (Gasoline direct injection with stratified charge) 

Shown on transfer case with CODE 430 (On & off-road package) 

	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 bolted connections with self tapping screws		AH00.00-P-0007-01SF
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Notes on automatic transmission		AH27.19-P-0001-01NKB
	Remove/install
1	Set DIRECT SELECT selector lever to position "N"
2	Release parking brake
3	Disconnect battery ground cable		AR54.10-P-0003GZ
	Notes on battery		AH54.10-P-0001-01A
4	Secure vehicle on vehicle lift		AR00.60-P-0100GZ
5	Remove respective section of the underfloor paneling		AR61.30-P-1001GQ
6	Remove left and right bracket of underfloor paneling from front axle carrier	TRANSMISSION 722.9 in MODEL 166 with ENGINE 276.8
7	Detach exhaust gas recirculation lines (4a, 4b) from exhaust system	ENGINE 276.9 with CODE 920 (Gasoline direct injection with stratified charge)
			AR49.10-P-7100GQA
8	Remove left and right bracket securing catalytic converter to transmission	TRANSMISSION 722.9 in MODEL 166 with ENGINE 276.8
		Screw/bolt, exhaust system bracket to transmission	*BA49.10-P-1020-01AK
9	Detach holder (5a, 5b) from transmission (1)	ENGINE 276.9 with CODE 920 (Gasoline direct injection with stratified charge)
10.1	Detach rear exhaust system at connecting point (arrows) and remove	ENGINE 276.9 with CODE 920 (Gasoline direct injection with stratified charge)
			AR49.10-P-7100GQA
10.2	Detach catalytic converter from center muffler	ENGINE 276.9 except CODE 920 (Gasoline direct injection with stratified charge)
10.3	Detach exhaust system at connecting point between diesel particulate filter and exhaust pipe and remove	ENGINE 642, 651	AR49.10-P-7100GQB
10.4	Remove rear exhaust system at connecting point of catalytic converter	ENGINE 276.8
			AR49.10-P-7100GQA
11	Unclip electrical line of left oxygen sensor downstream of catalytic converter from transmission (1)	ENGINE 157, 276.9, 278
12	Remove temperature sensor upstream of diesel particulate filter and place to one side	ENGINE 642, 651
			AR07.04-P-0005OGR
13	Remove heat shield (12) from transfer case (15)
14	Remove rear propeller shaft (6b) at output flange to rear axle from transfer case (15) or adapter housing, place to one side and fix in place		AR41.10-P-0050-17GZ
		Mark the rear propeller shaft (6b) relative to the propeller shaft flange. Observe the tightening procedure for the rear propeller shaft (6b) to the transfer case (15) or adapter housing.
		Self-locking bolt for propeller shaft on transfer case (to rear axle)	*BA41.10-P-1001-01F
		Retainer wrench	Fig 8
15	Remove front propeller shaft (6a) to front axle from output flange of transfer case, place to one side and fix in place	Except MODEL 166.058	AR41.10-P-0070-03GZ
		Observe tightening procedure for front propeller shaft (6a).	*BA41.10-P-1003-01F
		Self-locking bolt, propeller shaft to transfer case (to front axle)	*BA41.10-P-1003-01F
		Retainer wrench	Fig 8
16	Disconnect electrical connectors (15a) from transfer case (15) and unclip	Except MODEL 166.058
17	Disconnect electrical connector from intelligent servo module for DIRECT SELECT		AR27.19-P-0550GQ
18	Disconnect electrical connector from auxiliary oil pump (7)	With CODE B03 (ECO start/stop function)
			AR27.30-P-0651GQ
19	Unclip wiring harness from intelligent servo module at transmission (1)
20	Detach heat shield (8) from transmission (1)	MODEL 166 with TRANSMISSION 722.9
		MODEL 166.0 with TRANSMISSION 722.9	AR27.40-P-0700-01GZ
		Bolt, heat shield to transmission housing	*BA27.40-P-1014-01A
21	Disconnect electrical connector (9) from transmission (1) and detach wiring harness from transmission (1)
22	Detach oil cooling lines (10a, 10b) from transmission (1) and place to one side		AR27.55-P-0600GQ
23.1	Remove oil cooling line (10a) from thermostat	ENGINE 157, 276.9, 278
			AR27.55-P-0600GQ
23.2	Detach oil cooling lines (10a, 10b) from transmission bracket	ENGINE 276.8
24	Support transmission (1) with telescopic lifter and lash down securely	Transmission jack Transmission platform
25	Remove engine cross member at rear	TRANSMISSION 722.9 in MODEL 166
			AR22.10-P-1180GQ
26	Remove cover (11) and detach torque converter (2) from driver spider		AR27.20-P-0100-01A
		Bolt, torque converter to driver spider	*BA27.20-P-1002-01C
		Motor 651 Counterholder	Fig 4
		Socket wrench bit	Fig 9
		Long wedge	Fig 5
27	Pry torque converter (2) evenly off driver spider	Long wedge	Fig 5
28	Remove bracket for right oxygen sensor cable duct from torque converter housing	ENGINE 276.8
29	Remove bracket for left oxygen sensor connector from torque converter housing	ENGINE 276.8
30	Detach starter from transmission (1)	ENGINE 157, 278	AR15.30-P-7100MLJ
		ENGINE 276	AR15.30-P-7100GQ
		ENGINE 642	AR15.30-P-7100OGR
		ENGINE 651 Place starter to the side with lines connected and secure to prevent it falling down.	AR15.30-P-7100CD
31	Remove bolts from circumference of transmission (1)	Bolt, automatic transmission to engine	*BA27.40-P-1008-01A
32	Remove transmission (1) with transfer case (15) or adapter housing	Lower the telescopic lifter slowly and secure the torque converter (2) to prevent it from falling out. Align the bores of the torque converter (2) with the bores in the driver spider.
33	Remove torque converter (2)	MODEL 166 with TRANSMISSION 722.9 (except 722.93) If necessary
			AR27.20-P-0500-01W
		Observe the installation height of the torque converter.
		Installed height of torque converter	*BE27.20-P-1001-01E
		Handles	Fig 7
		Parallel rest	Figure
34	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
35	Check threaded unions in driver spider	If threaded unions are damaged or loose: Install a new driver spider.
		MODEL 166 with ENGINE 642 with TRANSMISSION 722.9	AR03.30-P-8001OGR
		MODEL 166 with ENGINE 157 with TRANSMISSION 722.9 MODEL 166 with ENGINE 278 with TRANSMISSION 722.9	AR03.30-P-8001MLJ
		MODEL 166 with ENGINE 276 with TRANSMISSION 722.9	AR03.30-P-8001GQ
		MODEL 166 with ENGINE 651 with TRANSMISSION 722.9	AR03.30-P-8001CD
36	Install in the reverse order
37	Check transmission oil level and correct if necessary		AR27.00-P-0270W
		Follow the prescribed work procedure exactly and observe the Specifications for Operating Fluids. The transmission (1) will otherwise be damaged.
38	Read out fault memory using diagnostic system and clear if necessary
			AD00.00-P-2000-04A
39	Perform transmission adaptation using diagnostic system	After replacement or repair of transmission (1)
40	Reset service life data of torque converter lockup clutch using diagnostic system	After replacing torque converter (2)
	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
41	Test run engine and check transmission (1) for leaktightness and proper operation

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

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

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	-

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

Number	Designation			MODEL 166
BA41.10-P-1001-01F	Self-locking bolt for propeller shaft on transfer case (to rear axle)	Stage 1	Nm	40
		Stage 2	∠°	90

Number	Designation			MODEL 166
BA41.10-P-1003-01F	Self-locking bolt, propeller shaft to transfer case (to front axle)	Stage 1	Nm	40
		Stage 2	∠°	90

Number	Designation			ENGINE 276 in MODEL 166
BA49.10-P-1020-01AK	Screw/bolt, exhaust system bracket to transmission	Stage 1	Nm	8
		Stage 2	∠°	90

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	-