Remove/Install, Disassemble/Assemble Intermediate Housing - AR27.40-P-0500EH

TRANSMISSION 724.2

MODIFICATION NOTES

20.01.2017

Repair method has been revised

Operation steps 4.1, 4.2, 7, 19, 21.1 and 21.2 newly added

Shown on transmission 724.2 with code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUG-IN))

	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
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Notes on automatic transmission		AH27.19-P-0001-01NKB
	Remove
1	Remove transmission	Transmission 724.2 in model 166	AR27.10-P-0005GQA
		Transmission 724.2 in model 205 with engine 274.9	AR27.10-P-0502LWH
		Transmission 724.2 in model 205 with engine 651	AR27.10-P-0502RFH
		Transmission 724.2 in model 222 with engine 651	AR27.10-P-0502LFY
		Transmission 724.2 in model 222 with engine 276	AR27.10-P-0502LFH
		Transmission 724.2 in model 253 with engine 274.9	AR27.10-P-0005LVH
		Transmission 724.2 in model 212.095/195 with engine 276.9 Transmission 724.2 in model 212.098/298 with engine 651.9	AR27.10-P-0502EH
2	Secure transmission to assembly device		AR27.10-P-0600-01EH
		Lifting device	Fig 5
		Assembly device	Fig 1
3	Unscrew bolts (2)
4.1	Insert guide pin (24) facing each other into housing of electric machine (4)	Transmission 724.2 in model 166, 222, 253 with code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN)) Transmission 724.2 in model 205 with code ME06 (Hybrid drive 60 kW variant (incl. plugin)) Guide bolts	Fig 3
4.2	Screw guide pins facing each other into the intermediate housing (1)	Transmission 724.2 in model 205, 212, 222 with code ME04 (Mild hybrid drive) Guide bolts	Fig 6
5.1	Carefully release intermediate housing (1) from electrical machine housing (4) using a plastic mallet and assembly wedge and remove with guide pin (24)	Transmission 724.2 in model 166, 222, 253 with code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN)) Transmission 724.2 in model 205 with code ME06 (Hybrid drive 60 kW variant (incl. plugin)) Do not pry off the intermediate housing (1) using a sharp-edged tool. The sealing surfaces can be damaged otherwise. Do not damage the high-voltage line when removing the intermediate housing (1). Secure pilot bushing (5) against falling down. Mounting wedge	Fig 4
5.1		Guide bolts	Fig 3
5.2	Carefully release intermediate housing (1) from electrical machine housing (4) using a plastic mallet and assembly wedge and remove.	Transmission 724.2 in model 205, 212, 222 with code ME04 (Mild hybrid drive) Do not pry off the intermediate housing (1) using a sharp-edged tool. The sealing surfaces can be damaged otherwise. Do not damage the high-voltage line when removing the intermediate housing (1). Mounting wedge	Fig 4
6	Remove guide pin from intermediate housing (1)	Transmission 724.2 in model 205, 212, 222 with code ME04 (Mild hybrid drive) The pilot bushings (5) must be secured against falling down. Guide bolts	Fig 6
7	Fit protective cap and cover up the exposed electric machine	Take particular care when covering up electric machine. Otherwise, ingressing dirt may damage it. Protective cap	Fig 2
	Disassemble/assemble
8	Remove fit bolt (6) and bolts (7)	Carefully release fit screw (6) and bolts (7) then remove. The coils of the electrical machine rotor position sensor (L20) can otherwise be damaged. Assembly : Do not mix up the fit bolt (6) and bolts (7). Correct operation of the electrical machine rotor position sensor (L20) can otherwise not be guaranteed. Assembly : The fit screw (6) and bolts (7) have to be replaced. Bolt, turning angle sensor to connecting flange	*BA27.10-P-1017-04G
9	Remove bolts (8) and remove retaining clamp (9)	Assembly : Bolts (8) must be replaced. Bolt, turning angle sensor to connecting flange	*BA27.10-P-1017-04G
10	Remove electric machine rotor position sensor (L20) and check for damage	If damage is present Replace electric machine rotor position sensor (L20).
11	Unclip holder (10) on catch hook (22) of plug (23) for electric machine rotor position sensor (L20)	When replacing the electrical machine rotor position sensor (L20). Assembly : Note installation position of electric lines for electric machine rotor position sensor (L20). Check plug (23) is correctly seated in shackle of holder (10) (arrows A).
12	Remove axial bearing (12) and check for wear and damage	In event of excessive wear or damage ↓ Replace axial bearing (12).
13	Remove bolts (13) and remove oil pump (11) from intermediate housing (1)	Assembly : Bolts (13) must be replaced. Assembly : The holes for the oil pump (11) must be lined up with the threaded connection hole pattern. Screw/bolt, oil pump to intermediate housing	*BA27.10-P-1016-04G
14	Remove bolts (15) and remove oil displacer (14) from intermediate housing (1)	Bolt, positive-displacement oil pump to connecting flange	*BA27.10-P-1018-04G
15	Remove bolts (17) and remove cover plate (16) from intermediate housing (1)	Bolt, cover plate to connecting flange	*BA27.10-P-1019-04G
16	Check sealing plate (19) for damage	Assembly : The sealing plate (19) must not be bent and may not exhibit any scratches, kinks or any other damage. Otherwise leakage is not possible. Assembly : Do not apply any sealant to the sealing plate (19). Otherwise leakage is not possible. If damage is present ↓ Replace sealing plate (19).
17	Remove radial shaft sealing ring (18)	The radial shaft sealing ring (18) must be replaced.	AR27.40-P-0300EH
18	Assemble in the reverse order
	Install
19	Remove protective cap from electric machine	Protective cap	Fig 2
20	Screw guide pins facing each other into the intermediate housing (1)	Transmission 724.2 in model 205, 212, 222 with code ME04 (Mild hybrid drive) Guide bolts	Fig 6
21.1	Insert guide pins (24) facing each other into intermediate housing (1) and position intermediate housing (1) on housing of electric machine (4)	Transmission 724.2 in model 166, 222, 253 with code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN)) Transmission 724.2 in model 205 with code ME06 (Hybrid drive 60 kW variant (incl. plugin)) When positioning the intermediate housing (1) pay attention to the routing of the interlock lines (20). The interlock lines (20) will otherwise be pinched which will cause damage. When positioning the intermediate housing (1), turn the drive shaft (21) so that the drivers (arrows B) of the oil pump (11) engage in the notches (arrows C) on the drive shaft (21). The pilot bushings (5) must be secured against falling down. Guide bolts	Fig 3
21.2	Position intermediate housing (1) onto housing of electric machine (4)	Transmission 724.2 in model 205, 212, 222 with code ME04 (Mild hybrid drive) When positioning the intermediate housing (1), pay attention to the routing of the interlock lines (20). The interlock lines (20) will otherwise be pinched which will cause damage. When positioning the intermediate housing (1), turn the drive shaft (21) so that the drivers (arrows B) of the oil pump (11) engage in the notches (arrows C) on the drive shaft (21).
22.1	Remove the guide pins (24) from the housing of the electric machine (4)	Transmission 724.2 in model 166, 222, 253 with code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN)) Transmission 724.2 in model 205 with code ME06 (Hybrid drive 60 kW variant (incl. plugin)) Guide bolts	Fig 3
22.2	Remove guide pin from intermediate housing (1)	Transmission 724.2 in model 205, 212, 222 with code ME04 (Mild hybrid drive) Guide bolts	Fig 6
23	Tighten bolts (2)	Bolt, connecting flange to coupling housing	*BA27.10-P-1002-04G
24	Perform measurement on insulation resistance of electric machine, fill out the error list and add to the repair documentation	Transmission 724.2 in model 166, 222, 253 with code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN)) Transmission 724.2 in model 205, 212, 222 with code ME04 (Mild hybrid drive) Transmission 724.2 in model 205 with code ME06 (Hybrid drive 60 kW variant (incl. plugin))
	Test log for insulation resistance measurement, form		OF27.19-P-3000-01A
			AR08.10-P-0004-01MRD
		Electric machine insulation resistance	*BE08.10-P-1003-01A
25	Detach transmission from assembly device	Lifting device	Fig 5
25	Detach transmission from assembly device	Assembly device	Fig 1
26	Install transmission	Transmission 724.2 in model 166	AR27.10-P-0005GQA
		Transmission 724.2 in model 205 with engine 274.9	AR27.10-P-0502LWH
		Transmission 724.2 in model 205 with engine 651	AR27.10-P-0502RFH
		Transmission 724.2 in model 222 with engine 651	AR27.10-P-0502LFY
		Transmission 724.2 in model 222 with engine 276.9	AR27.10-P-0502LFH
		Transmission 724.2 in model 253 with engine 274.9	AR27.10-P-0005LVH
		Transmission 724.2 in model 212.095/195 with engine 276.9 Transmission 724.2 in model 212.098/298 with engine 651.9	AR27.10-P-0502EH
27	Connect diagnostic system and perform sensor rotor adaptation	When replacing the electrical machine rotor position sensor (L20).
		Transmission 724.2 in model 205, 222, 253	AD00.00-P-2000-04B
		Transmission 724.2 in model 166, 212	AD00.00-P-2000-04A