Remove/Install Transmission With Torque Converter - AR27.10-P-0500GN
TRANSMISSION 725.0 in MODEL 166 with ENGINE 651
TRANSMISSION 725.0 in MODEL 166, 292 with ENGINE 276
TRANSMISSION 725.0 in MODEL 166, 292 with ENGINE 278
TRANSMISSION 725.0 in MODEL 166, 292 with ENGINE 642
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 | |
| Risk of injury . Moving parts can pinch, crush or, in extreme cases even sever extremities. | No parts of the body or limbs should be within the operating area of mechanical components when moving components. | AS00.00-Z-0009-01A | |
| 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 | |
| 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 | |
| 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 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 | |||
| 1 | Shift transmission (1) into neutral position | ||
| 2 | Release parking brake and secure vehicle to prevent it from rolling | ||
| 3 | Disconnect ground line from battery | AR54.10-P-0003GZ | |
| 4 | Secure vehicle on vehicle lift | AR00.60-P-0100GZ | |
| 5 | Remove the diesel particulate filter | Transmission 725.0 in model 166, 292 with engine 642 | AR49.10-P-5501OGR |
| 6.1 | Remove the exhaust system | Transmission 725.0 in model 166 with engine 651 Transmission 725.0 in model 166, 292 with engine 642 Transmission 725.0 in model 292 with engine 642 |
AR49.10-P-7142OGR |
| Transmission 725.0 in model 166 with engine 642 Transmission 725.0 in model 166 with engine 651 |
AR49.10-P-7100GQB | ||
| 6.2 | Remove exhaust system center | Transmission 725.0 in model 166, 292 with engine 276 Transmission 725.0 in model 166, 292 with engine 278 |
AR49.10-P-7283MLJ |
| 7 | Remove left and right exhaust system brackets from transmission (1) | Transmission 725.0 in model 166, 292 with engine 276 | |
| 8 | Detach heat shield (8) from transmission (1) | AR27.40-P-0700-01GZ | |
| 9 | Release and detach electrical connection (9) from transmission (1) and remove wiring harness from transmission (1) | ||
| 10 | Detach oil lines (10a, 10b) from transmission (1) and place to one side | AR27.55-P-0600GQ | |
| 11 | Release and disconnect electrical connection from auxiliary oil pump (7) | Transmission 725.0 in model 166, 292 with engine 642 with code B03 (ECO start/stop function) |
|
| 12 | Detach additional oil filter with bracket and place to one side with lines connected | Transmission 725.0 in model 292 with engine 276 Transmission 725.0 in model 292 with engine 278 Transmission 725.0 in model 292 with engine 642 If installed. |
AR27.56-P-0202AVG |
| 13 | Remove cover (11) | ||
| 14 | Remove torque converter (2) from drive plate | AR27.20-P-0001-01EWM | |
| Fig 5 | |||
| Fig 3 | |||
| 15 | Remove heat shield (12) from transfer case (15) | Transmission 725.0 in model 166 with engine 651 with code 430 (On & off-road package) Transmission 725.0 in model 166, 292 with engine 276.8 with code 430 (On & off-road package) Transmission 725.0 in model 166, 292 with engine 278 with code 430 (On & off-road package) Transmission 725.0 in model 166, 292 with engine 642 with code 430 (On & off-road package) |
|
| 16 | Remove rear drive shaft (6b) from output flange of transfer case (15) or adapter housing, place to one side and fix in place | AR41.10-P-0050-17GZ | |
| Figure | |||
| 17 | Remove front propeller shaft (6a) from output flange of transfer case (15), place to one side and fix in place | Transmission 725.0 in model 166 (except 166.006) with engine 651 Transmission 725.0 in model 166 (except 166.058), 292 with engine 276 Transmission 725.0 in model 166, 292 with engine 278 Transmission 725.0 in model 166, 292 with engine 642 |
AR41.10-P-0070-03GZ |
| Figure | |||
| 18 | Release, detach and unclip electrical connections (15a) on transfer case (15) | Transmission 725.0 in model 166 with engine 651 with code 430 (On & off-road package) Transmission 725.0 in model 166, 292 with engine 276 with code 430 (On & off-road package) Transmission 725.0 in model 166, 292 with engine 278 with code 430 (On & off-road package) Transmission 725.0 in model 166, 292 with engine 642 with code 430 (On & off-road package) |
|
| 19 |
Prop up and strap down transmission (1) using major-assembly support and mounting plate 000 588 11 62 00 Major assembly mount | WS01.00-P-0092B | |
| 000 588 10 62 00 Support plate | WS26.00-P-3309B | ||
| 20 | Remove rear engine crossmember | Transmission 725.0 in model 166 with engine 276 Transmission 725.0 in model 166 with engine 642 Transmission 725.0 in model 166 with engine 651 Transmission 725.0 in model 166, 292 with engine 278 Transmission 725.0 in model 292 with engine 276 |
AR22.10-P-1180GQ |
| Transmission 725.0 in model 292 with engine 642 | AR22.10-P-4360OGR | ||
| 21 | Unfasten starter wiring harness from transmission (1) | ||
| 22 | Remove starter from transmission (1), place to one side with lines attached and secure against falling down | Transmission 725.0 in model 166 with engine 276.9 | AR15.30-P-7100GQA |
| Transmission 725.0 in model 166 with engine 651 | AR15.30-P-7100CD | ||
| Transmission 725.0 in model 166, 292 with engine 276.8 | AR15.30-P-7100GQ | ||
| Transmission 725.0 in model 166, 292 with engine 278 | AR15.30-P-7100MLJ | ||
| Transmission 725.0 in model 166, 292 with engine 642 | AR15.30-P-7100OGR | ||
| 23 | Remove screws fastening transmission (1) to engine | ||
| 24 |
Remove transmission (1) with transfer case (15) 000 588 11 62 00 Major assembly mount |
WS01.00-P-0092B | |
| 000 588 10 62 00 Support plate | Secure torque converter (2) against falling down. Damage will otherwise occur. |
WS26.00-P-3309B | |
| 25 | Remove torque converter (2) | If necessary. | AR27.20-P-0500-01EWM |
| Figure | |||
| 26 | Remove corrosion from crankshaft | AR03.20-P-1000-01A | |
| Multi-purpose paste | *BR00.45-Z-1009-06A | ||
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| 27 | Check threaded unions on drive plate for damage and loose fit | If threaded unions are damaged or loose ↓ Replace drive plate. Transmission 725.0 in model 166 with engine 651 |
AR03.30-P-8001CD |
| Transmission 725.0 in model 166, 292 with engine 276 | AR03.30-P-8001GQ | ||
| Transmission 725.0 in model 166, 292 with engine 278 | AR03.30-P-8001MLJ | ||
| Transmission 725.0 in model 166, 292 with engine 642 | AR03.30-P-8001OGR | ||
| Install | |||
| 28 | Insert torque converter (2) into transmission (1) | After removal of torque converter (2). | AR27.20-P-0500-01EWM |
| Grease, silicone-based, 100 g | *BR00.45-Z-1008-06A | ||
| Figure | |||
| Figure | |||
| 29 |
Install transmission (1) with transfer case (15) 000 588 10 62 00 Support plate | WS26.00-P-3309B | |
| 000 588 11 62 00 Major assembly mount | Secure torque converter (2) against falling down. Damage will otherwise occur. |
WS01.00-P-0092B | |
| 30 | Tighten screws fastening transmission (1) to engine | *BA27.10-P-1001-04H | |
| 31 | Release mounting of starter and mount starter onto transmission (1) | Transmission 725.0 in model 166 with engine 276.9 | AR15.30-P-7100GQA |
| Transmission 725.0 in model 166 with engine 651 | AR15.30-P-7100CD | ||
| Transmission 725.0 in model 166, 292 with engine 276.8 | AR15.30-P-7100GQ | ||
| Transmission 725.0 in model 166, 292 with engine 278 | AR15.30-P-7100MLJ | ||
| Transmission 725.0 in model 166, 292 with engine 642 | AR15.30-P-7100OGR | ||
| 32 | Fasten starter wiring harness at transmission (1) | ||
| 33 | Install rear engine crossmember | Transmission 725.0 in model 166 with engine 276 Transmission 725.0 in model 166 with engine 642 Transmission 725.0 in model 166 with engine 651 Transmission 725.0 in model 166, 292 with engine 278 |
AR22.10-P-1180GQ |
| Transmission 725.0 in model 292 with engine 276 Transmission 725.0 in model 292 with engine 642 |
AR22.10-P-4360OGR | ||
| 34 |
Release strapping on transmission (1) and lower major-assembly support and mounting plate 000 588 10 62 00 Support plate |
WS26.00-P-3309B | |
| 000 588 11 62 00 Major assembly mount | WS01.00-P-0092B | ||
| 35 | Connect, lock and clip in electrical connectors (15a) at transfer case (15) | Transmission 725.0 in model 166 with engine 651 with code 430 (Rear head restraints) Transmission 725.0 in model 166, 292 with engine 276 with code 430 (On & off-road package) Transmission 725.0 in model 166, 292 with engine 278 with code 430 (On & off-road package) Transmission 725.0 in model 166, 292 with engine 642 with code 430 (On & off-road package) |
|
| 36 | Release fastening for front propeller shaft (6a) and mount front propeller shaft (6a) onto output flange of transfer case (15) | Transmission 725.0 in model 166 (except 166.006) with engine 651 Transmission 725.0 in model 166 (except 166.058), 292 with engine 276 Transmission 725.0 in model 166, 292 with engine 278 Transmission 725.0 in model 166, 292 with engine 642 |
AR41.10-P-0070-03GZ |
| *BA41.10-P-1004-01F | |||
| *BA41.10-P-1003-01F | |||
| Figure | |||
| 37 | Release fastening for rear drive shaft (6b) and mount rear drive shaft (6b) onto output flange of transfer case (15) or adapter housing | AR41.10-P-0050-17GZ | |
| *BA41.10-P-1001-01F | |||
| Figure | |||
| 38 | Attach heat shield (12) to transfer case (15) | Transmission 725.0 in model 166 with engine 651 with code 430 (On & off-road package) Transmission 725.0 in model 166, 292 with engine 276 with code 430 (On & off-road package) Transmission 725.0 in model 166, 292 with engine 278 with code 430 (On & off-road package) Transmission 725.0 in model 166, 292 with engine 642 with code 430 (On & off-road package) |
|
| 39 | Mount torque converter (2) onto drive plate | AR27.20-P-0001-01EWM | |
| *BA27.20-P-1001-01D | |||
| Fig 5 | |||
| Fig 3 | |||
| 40 | Install cover (11) | ||
| 41 | Mount auxiliary oil filter with bracket | Transmission 725.0 in model 292 with engine 276 Transmission 725.0 in model 292 with engine 278 Transmission 725.0 in model 292 with engine 642 If installed. |
AR27.56-P-0202AVG |
| 42 | Connect and lock electrical connector at auxiliary oil pump (7) | Transmission 725.0 in model 166, 292 with engine 642 with code B03 (ECO start/stop function) |
|
| 43 | Attach oil lines (10a, 10b) to transmission (1) | AR27.55-P-0600GQ | |
| 44 | Connect and lock electrical connector (9) at transmission (1), and attach wiring harness to transmission (1) | ||
| 45 | Mount heat shield (8) onto transmission (1) | AR27.40-P-0700-01GZ | |
| 46 | Attach left and right exhaust system brackets to transmission (1) | Transmission 725.0 in model 166, 292 with engine 276 |
*BA49.10-P-1020-01AK |
| 47.1 | Install exhaust system | Transmission 725.0 in model 166 with engine 651 Transmission 725.0 in model 166, 292 with engine 642 Transmission 725.0 in model 292 with engine 642 |
AR49.10-P-7142OGR |
| Transmission 725.0 in model 166 with engine 642 Transmission 725.0 in model 166 with engine 651 |
AR49.10-P-7100GQB | ||
| 47.2 | Install center of exhaust system | Transmission 725.0 in model 166, 292 with engine 276 Transmission 725.0 in model 166, 292 with engine 278 |
AR49.10-P-7283MLJ |
| 48 | Install diesel particulate filter | Transmission 725.0 in model 166, 292 with engine 642 | AR49.10-P-5501OGR |
| 49 | Check oil level in transmission (1) and correct, if necessary | Transmission 725.0 in model 166 with engine 651 as of model year 2015 Transmission 725.0 in model 166, 292 with engine 276 as of model year 2015 Transmission 725.0 in model 166, 292 with engine 278 as of model year 2015 Transmission 725.0 in model 166, 292 with engine 642 as of model year 2015 |
AR27.00-P-0270EWN |
| Transmission 725.0 in model 166 with engine 651 up to model year 2015 Transmission 725.0 in model 166, 292 with engine 276 up to model year 2015 Transmission 725.0 in model 166, 292 with engine 278 up to model year 2015 Transmission 725.0 in model 166, 292 with engine 642 up to model year 2015 |
AR27.00-P-0270EWM | ||
| 50 | Remove vehicle lift safety device, and lower vehicle | AR00.60-P-0100GZ | |
| 51 | Connect ground lead to battery | AR54.10-P-0003GZ | |
| 52 |
Perform transmission adaptation using diagnostic system | After replacement or repair of transmission (1). | AD00.00-P-2000-04A |
| 53 |
Reset data on service life of torque converter lockup clutch using diagnostic system | After replacement of torque converter (2). | AD00.00-P-2000-04A |
| Check | |||
| Risk of burn injuries , suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust. | Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area. | AS49.00-Z-0001-01A | |
54 |
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. Conduct engine test run, and check transmission (1) for leak tightness and proper operation |
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 |
AUTOMATIC TRANSMISSION COMPLETE
| Number | Designation | Transmission 725.0 | |
|---|---|---|---|
| BA27.10-P-1001-04H | Screw/bolt, transmission to engine | Nm | 39 |
TORQUE CONVERTER
| Number | Designation | Transmission 725.0 | ||
|---|---|---|---|---|
| BA27.20-P-1001-01D | Bolt, torque converter to Angled threaded drive plate/star-shaped connection drive plates | Stage 1 | Nm | 3 |
| Stage 2 | Nm | 30 | ||
| Stage 3 | ∠° | 90 | ||
PROPELLER SHAFT
| Number | Designation | Model 166 | Model 292 | ||
|---|---|---|---|---|---|
| BA41.10-P-1001-01F | Self-locking screw/bolt of propeller shaft at transfer case/adapter housing (to rear axle) | Stage 1 | Nm | 40 | 40 |
| Stage 2 | ∠° | 90 | 90 | ||
PROPELLER SHAFT
| Number | Designation | Model 166 | Model 292 | ||
|---|---|---|---|---|---|
| BA41.10-P-1003-01F | Self-locking bolt, drive shaft to transfer case (to front axle) | Stage 1 | Nm | 40 | 40 |
| Stage 2 | ∠° | 90 | 90 | ||
PROPELLER SHAFT
| Number | Designation | Model 166 | Model 292 | ||
|---|---|---|---|---|---|
| BA41.10-P-1004-01F | Self-locking bolt, drive shaft to transfer (to front axle) | Stage 1 | Nm | 40 | 40 |
| Stage 2 | ∠° | 90 | 90 | ||
EXHAUST SYSTEM
| Number | Designation | Engine 276 in model 166 | Engine 276 in model 292 | ||
|---|---|---|---|---|---|
| BA49.10-P-1020-01AK | Bolt, exhaust system bracket to transmission | Stage 1 | Nm | 8 | 8 |
| Stage 2 | ∠° | 90 | 90 | ||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1008-06A | Grease, silicone-based, 100 g | A 001 989 28 51 |
| BR00.45-Z-1009-06A | Multi-purpose paste | A 000 989 80 51 |
| BR00.45-Z-1028-04A | Assembly cleaner | Adolf Wurth GmbH & Co. KG |