Measure/Install Dual Clutch Transmission Gear Set - AR27.50-P-0900-01NKB

Transmission 724 in model 117, 118, 156, 176, 177, 242, 246, 247 

Fig 1: Identifying Support Fixture (724 589 02 31 00)

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Fig 2: Identifying Adapter (724 589 00 16 00)

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Fig 3: Identifying Parallel Support (168 589 03 21 00)

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Cleaning

1. Thoroughly clean face and contact surfaces at transmission housing and coupling housing using Loctite 7200 and Loctite 7063 cleaning spray.

   Do not use any sharp-edged tools or abrasive paper.

   Otherwise, the face and contact surfaces may be damaged.

   Check for absolute cleanliness.

   Measurement errors which can result in damage to the transmission will otherwise occur.

   Measure

2. support fixture (01) on transmission housing (27G).
3. Insert bearing shells from coupling housing into thrust piece (D50, D60, D80).

   Inset the bearing shells that are to be inserted into the coupling housing before installation into the support fixture (01).

4. • 4.1  Transmission 724 in model 117, 118, 156, 176, 177, 242, 246, 247

     Place driver (02k) of turning device (01k) onto differential shaft.

   • 4.2  Transmission 724 in model 117, 156, 176 with engine 133 with code 471 (AMG front axle differential lock)

     Place adapter of turning device (01k) onto shaft of differential.

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5. Mount thrust pieces (D50, D60, D80) with bearing shells onto shafts.
6. Screw in spindles (01s) of support fixture (01) until they lie up against the transmission shafts, and the lower edges of the circumferential grooves (01 n) are covered by the thrust sleeves (01 d).

   Ensure they are covered up accurately.

   Measurement errors which can result in damage to the transmission will otherwise occur.

7. Turn main shaft of transmission using turning device 20 to 30 times.

   When turning the main shaft the transmission mounts settle, so that a correct measurement is then possible.

8. Set digital vernier caliper to zero position (A).

   The zero position (A) is the dimension from each bore (a, b, c) the support fixture (01) at the top up to the sealing flange on the transmission housing (27G).

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9. Measure gear set using digital Vernier caliper (1x) and note down values.

   Measure gear set at each of the measuring bores (1a, 1b, 1c) of the support fixture to each thrust piece (D50, D60, D80).

   Ignore the negative sign.

10. Form the mean value from the measurement values and note down.

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11. Place parallel gauges on sealing flange of dutch housing (27K).

    Position parallel gauges in center over the bearing seat to be measured.

12. Set digital vernier caliper to zero position.

    The zero position is the dimension from the parallel gauges to the sealing flange on the clutch housing (27K).

13. Measure bearing seat in clutch housing (27K) using digital vernier caliper and note down values.

    Measure bearing seats at two opposing points from sealing surface to lower bearing seat (50M, 60M, 80M).

14. Form the mean value from the measurement values and note down.
15. Calculate shim thickness "S" of differential.

    Calculate shaft gap dimension for differential: 

    The mean value for the dimension of the support fixture to the differential thrust piece minus the basic dimension of the thrust piece (differential) gives the shaft gap dimension.

    Calculation example: 65.36 mm -25.00 mm = 40.36 mm.

    Calculate adjusting disk size "S" for differential: 

    The mean value from the coupling housing (27K) to the bearing seat minus the shaft distance dimension plus the tolerance value gives the shim thickness "S".

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    Calculation example: 41.46 mm -40.36 mm + 0.10 mm = 1.20 mm.

    Spacer rings are available in thicknesses from 1.1 to 1.75 mm in graduations of 0.05 mm. In the above-mentioned calculation example, a spacer ring with a thickness of 1.20 mm is installed on the differential.

16. Calculate shim thickness "S" of spacer rings for 1st, 2nd, 4th, 5th gear on power output shaft (located in transmission housing at bottom).

    Calculate shaft gap dimension: 

    The mean value from the dimension of the support fixture to the differential thrust piece minus the basic dimension of the thrust piece (1st, 2nd, 4th, 5th gear on power output shaft) gives the shaft gap dimension.

    Calculation example: 32.92 mm -25.00 mm = 7.92 mm.

    Calculate adjusting disk size for 1st, 2nd, 4th and 5th gear on power output shaft: 

    The mean value from the coupling housing (27K) to the bearing seat minus the shaft distance dimension plus the tolerance value gives the shim thickness "S".

    Calculation example: 9.01 mm -7.92 mm + 0.18 mm = 1.27 mm.

    Spacer rings are available in thicknesses from 1.10 to 1.90 mm in graduations of 0.05 mm. In the above-mentioned calculation example, a spacer ring with a thickness of 1.30 mm is installed on the differential.

17. Calculate shim thickness "S" of spacer rings of 3rd, 6th, 7th gear on power output shaft and reverse gear (located in transmission housing at top).

    Calculate shaft gap dimension: 

    The mean value from the dimension of the Support fixture to the differential thrust piece minus the basic dimension of the thrust piece (3rd, 6th, 7th gear on power output shaft and reverse gear) gives the shaft gap dimension.

    Calculation example: 36.60 mm -25.00 mm = 11.60 mm.

    Calculate adjusting disk size for 3rd, 6th, 7th and reverse gear output shaft: 

    The mean value from the coupling housing (27K) to the bearing seat minus the shaft distance dimension plus the tolerance value gives the shim thickness "S".

    12.78 mm - 11.60 mm + 0.16 mm = 1.34 mm.

    Spacer rings are available in thicknesses from 1.10 to 1.80 mm in graduations of 0.05 mm. In the above-mentioned calculation example, a spacer ring with a thickness of 1.35 mm is installed on the differential.