Attach Gear Set Housing To Differential Housing - AR27.40-P-0540-02RQ

Transmission 700.40

HOUSING

Number	Designation		TRANSMISSION 700.4 in MODEL 190	TRANSMISSION 700.4 in MODEL 197
BA27.40-P-1005-01F	Bolt, differential housing to gear set housing	Nm	34	34

HOUSING

Number	Designation		TRANSMISSION 700.4 in MODEL 190	TRANSMISSION 700.4 in MODEL 197
BA27.40-P-1006-01F	Bolt, connector plate to differential housing	Nm	10	10

Fig 1: Identifying Guide Bolts (700 589 06 15 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Lifting Device (700 589 05 63 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1013-01A	Loctite 5970 sealant	A 003 989 98 20
BR00.45-Z-1046-04A	Loctite 7063 cleaning spray (150 ml)	A 001 986 71 71 10

Lift differential housing (14) using a hoist and position so that it is horizontal by pushing lifting device (010) (arrow).
The differential housing (14) must hang horizontally from the hoist.

Otherwise, damage will occur when the gear set housing (15) and the differential housing (14) are joined together.

Use the fastening points (k) on the lifting device (010).

Use fastening points (l) on differential (14).

Courtesy of MERCEDES-BENZ USA
Clean sealing surface (1) of differential housing (14) using Loctite cleaning spray.
The sealing surface (1) must be clean, dry and free of dust and grease.
Screw guide pins into holes (a, b) on differential housing (14).

Courtesy of MERCEDES-BENZ USA
Clean sealing surface (2) of intermediate plate using Loctite cleaning spray.
The sealing surface (2) must be clean, dry and free of dust and grease.
Place shift mechanism hydraulic unit connector (12) on shift mechanism hydraulic unit.

Courtesy of MERCEDES-BENZ USA
Apply Loctite sealant evenly to sealing surface (2) on intermediate plate of gear set housing (15).
Sealant should be applied only to the specified sealing surface (2), in the form of a bead measuring 2 to 3 mm in height and width. The sealant bead must not be spread. Use only the sealant indicated in the repair materials. Mount the differential housing (14) within a period of 10 minutes after application of the sealant.

Courtesy of MERCEDES-BENZ USA

The following must be observed when assembling the differential and gear set housing (14, 15): Turning the drive shaft at the clutch housing and at the propeller shaft flange and moving the differential housing (14) to and fro will make it easier for the bevel gear (5) to engage in the ring gear (6). This also results in positive connection between the pin of the pump shaft (7) and the slot in the multipole wheel (8). If this is the case, the differential housing (14) will engage abruptly.

During assembly, transmission oil must not be allowed to come into contact with the previously-applied sealant bead.

Leaks can occur otherwise.

Courtesy of MERCEDES-BENZ USA
Slowly lower differential housing (14) while simultaneously inserting guide pins into holes (c, d).

Courtesy of MERCEDES-BENZ USA
Lower differential housing (14) further.
When doing so, make sure that the drive shaft (4) does not damage the clutch hydraulic unit (3).

The clutch hydraulic unit (3) must otherwise be replaced.

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA
Lower differential housing (14) further until dimension (f₁ ) is reached, guide clutch hydraulic unit connector through opening in differential housing (14).
Dimension (f₁ ) = approx. 110 mm.
Lower differential housing (14) further and carefully approach dimension (f₂ ) until resistance relieves hoist slightly.
Dimension (f₂ ) = approx. 50 mm.
Turn drive shaft at clutch housing and at propeller shaft flanges vigorously while simultaneously moving differential housing (14) to and fro.
The differential housing (14) drops down when the ring gear and pinion engage.
Move differential housing (14) further toward dimension (f₃ ) using hoist (alternatively lifting function of assembly stand (030) can also be used for joining together sections of transmission).
Turning the propeller shaft flange and drive shaft again allows the pin of the pump shaft to engage in the slot of the multipole wheel. The differential housing (14) engages abruptly and the sealing surface of the gear set housing (15) lies flush against the sealing surface of the differential housing (14).

Dimension (f₃ ) = approx. 5 mm.
Manually position M8x55 steel bolts (11a, 2 each) and M8x37 x steel bolt (11b, 1 each), then tighten by hand until increased resistance can be felt.
The gear set housing (15) must already lie flush against the differential housing (14) before the steel bolts (11a, 11b) are inserted.

Install new steel bolts (11a, 11b).
Tighten steel bolts (11a, 11b, 3 each) on gear set housing (15).
The gear set housing and differential housing (15, 14) must never be pulled together using the steel bolts (11a, 11b).

The shift mechanism hydraulic unit and the oil pump will otherwise be damaged.
Detach guide pins and lifting device (010).

Courtesy of MERCEDES-BENZ USA
Move transmission to horizontal position using assembly stand.
Position steel bolts (A to N) by hand in alphabetical order and tighten by hand until increased resistance can be felt.
Install new steel bolts (A to N).

M8x38 steel bolts: A, B, D, F, H, I, J, L, N, M8x55 steel bolts: C, E, G, K, M.
Tighten steel bolts (A to N) .
The transmission is shown here for better illustration without the gear set housing (15).

Courtesy of MERCEDES-BENZ USA
Replace O-rings (16) of shift mechanism hydraulic unit connector (9).
Assemble shift mechanism hydraulic unit connector (9) and connector plate (10).
When assembling, make sure that the electrical lines are not damaged on the sharp edges of the differential housing (14).

Otherwise the transmission may suffer malfunctions.

Install the shift mechanism hydraulic unit connector (9) and connector plate (10) at the correct position (pay attention to the tab (h) and notch (g)).
Insert electrical connection, consisting of hydraulic unit shift mechanism connector (9) and connector plate (10), into differential housing (14) and secure with bolts. .

Courtesy of MERCEDES-BENZ USA