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Disassemble, Assemble Transmission - AR27.10-P-0510MFC

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Transmission 724.0 in model 118, 177, 247 

MODIFICATION NOTES

22.01.2020 Detach power take-off from clutch housing (27K). Operation step 3  
G16063321Courtesy of MERCEDES-BENZ USA
G16063322Courtesy of MERCEDES-BENZ USA
G16063323Courtesy of MERCEDES-BENZ USA
G16063324Courtesy of MERCEDES-BENZ USA
G16063325Courtesy of MERCEDES-BENZ USA
G16063326Courtesy of MERCEDES-BENZ USA
CAUTION 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
CAUTION 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
Notice  Notes on avoiding damage through contamination and foreign objects   AH00.00-P-5000-01A
Notice  Notes on threaded connections fastened using a tightening angle-based tightening process   AH00.00-P-0020-01A
  Notes on automatic transmission   AH27.19-P-0001-01NKB 
REMOVING Remove     
1 Remove transmission.   AR27.10-P-0009MFC 
2 Fasten transmission onto assembly stand.   AR27.10-P-0600-01NKB 
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars IMPORTANTCommercially available devices/tools 
Workshop crane		 WS01.00-P-0262B
    SPECIAL TOOL Adapter Fig 6
    SPECIAL TOOL Assembly device Fig 2
    SPECIAL TOOL Assembly device Fig 9
DISASSEMBLINGASSEMBLING Disassemble/assemble     
3 Detach power take-off from clutch housing (27K). Transmission 724.0 in model 118, 177, 247 with code M005 (Vehicles with 4MATIC/all-wheel drive) AR27.45-P-0010-01MFC
    Assembly cleaner *BR00.45-Z-1028-04A 
4 Remove retainer ring (5). IMPORTANTAssembly:  Install new retaining ring (5).  
5 Remove cap with oil duct (6) from transmission housing (27G). IMPORTANTAssembly:  Install a new cover with oil duct (6).
SPECIAL TOOL Drift set		 Fig 11
6 Remove cap (7) from parking lock mechanism. IMPORTANTAssembly:  Install a new cover (7).
SPECIAL TOOL Drift set		 Fig 11
7 Remove oil cooling system cooling module.   AR27.55-P-1500MFC
8 Remove dual clutch transmission fully integrated transmission control electrohydraulic controller unit (Y3/14).   AR27.19-P-0200MFC 
9 Remove dual clutch.   AR27.20-P-0070MFC 
10 Remove oil pump gear (2) with puller from oil-pump drive shaft (00). NOTESAssembly: 
Replace oil pump gear (2) after each removal.
Otherwise the transmission will be damaged.
NOTES
Do not use an impact wrench or compressed air tool.
Otherwise the SPECIAL TOOL puller (00) and the shaft of the primary oil pump (55) will be damaged.
IMPORTANTAssembly:  Clean shaft on primary oil pump (55) as well as the contact surface between nut and oil pump gear (2).
The parts must be free of any grease, oil and dirt.
IMPORTANT Observe nut's direction of rotation (left-hand thread).		 AR27.10-P-0400-01NKB 
    TORQUE SPECIFICATION Nut (left-hand thread), oil pump gear to oil pump *BA27.10-P-1008-04F 
    Assembly cleaner *BR00.45-Z-1028-04A 
    SPECIAL TOOL Puller Fig 10
    SPECIAL TOOL Puller Fig 1
11 Unscrew screw (102s) and remove permanent magnet (102). IMPORTANTAssembly:  Replace the permanent magnet (102).
TORQUE SPECIFICATION Bolt, permanent magnet to reset piston		 *BA27.10-P-1010-04F 
12 Remove bolts (3, 4). TORQUE SPECIFICATION Bolt, clutch housing to transmission housing *BA27.10-P-1001-04F 
13 Pry clutch housing (27K) off transmission housing (27G) by applying a suitable tool at cutouts.    
14 Remove sealant from clutch housing (27K) and transmission housing (27G).   AR01.00-P-0050-01A
  Notes on application of flange sealants to seal major assemblies   AH00.00-P-0500-01MNE
  Notes on sealant path for transmission housing IMPORTANTAssembly:  Apply sealant on sealing surface of transmission housing (27G). Observe sealant path.
Replace seals of oil ducts (3 ea.).		 AH27.00-P-0100-01NKB 
    Loctite 7063 (400 ml) cleaning spray *BR00.45-Z-1046-04A 
    Loctite 7200 *BR00.45-Z-1038-04A 
    Sealant, Loctite 5970, 50 ml *BR00.45-Z-1013-01A 
    SPECIAL TOOL Application gun Fig 4
15 Note installation position of pilot bushings and remove pilot bushings from gearshifts (60S, 80S). IMPORTANTAssembly:  Install pilot bushings in the installation positions noted before removing.
If the installation positions of the pilot bushings cannot be clearly determined can be, e.g. because they dropped down when removing the clutch housing (27K),
↓
remove the gearshifts (60S, 80S).		  
16 Remove sensor rotor from hollow shaft (40) on primary oil pump (55) using puller. IMPORTANTAssembly:  Before installation of the oil pump gear (2), remove shaft from primary oil pump (55) and clean contact surface between nut and impeller.
IMPORTANT Observe nut's direction of rotation as it is a left-hand thread.		 AR27.10-P-0400-01NKB 
    Assembly cleaner *BR00.45-Z-1028-04A 
    TORQUE SPECIFICATION Nut, hollow shaft rotor to oil pump *BA27.10-P-1009-04F 
    SPECIAL TOOL Puller Fig 10
    SPECIAL TOOL Puller Fig 1
17 Remove primary oil pump (55).   AR27.10-P-0400MFC 
REFER TO CAPACITIES & SPECIFICATIONS Automatic transmission fluid (ATF) (specification 236.21) IMPORTANTAssembly:  Moisten seals of primary oil pump (55) before installation with transmission oil.
Replace the primary oil pump (55).		 BB00.40-P-0236-21A
18 Remove absolute pressure valve (56) and spring guide (57) from transmission housing (27G). IMPORTANTAssembly:  Note installation position of absolute pressure valve (56) and spring guide (57).
The spring guide (57) on the absolute pressure valve (56) (pictures A) must point toward the clutch housing (27K) when inserted into the transmission housing (27G).
If the absolute pressure valve (56) is inserted incorrectly, the park pawl will be damaged and will then break during commissioning (pictures B).		  
19 Check absolute pressure valve (56) and spring guide (57) for damage. If absolute pressure valve (56) or spring guide (57) is damaged,
↓
replace absolute pressure valve (56) and spring guide (57).		  
20 Install shaft carrier of assembly device (027). SPECIAL TOOL Assembly device Fig 2
21 Rotate assembly device (027). SPECIAL TOOL Assembly device Fig 2
22 Unfasten hold-down tool from assembly device (027). SPECIAL TOOL Assembly device Fig 2
23 Remove housing carrier of assembly device (027) from transmission housing (27G) and from basic carrier of assembly device (027). SPECIAL TOOL Assembly device Fig 2
24 Remove retaining ring (30S) from drive shaft (30). IMPORTANTAssembly:  Replace retaining ring (30S).
SPECIAL TOOL Pliers		 Fig 8
25 Remove dust screen (36S) from ball bearing (36) of drive shaft (30).    
26 Pry off transmission housing (27G) from drive shaft (30) using puller. NOTESAssembly: 
Check that the thrust piece is correctly seated on the drive shaft (30).
Otherwise the oil restrictor in the drive shaft (30) may be damaged.
IMPORTANTAssembly:  Replace ball bearing (36) and press onto drive shaft (30) before assembly of transmission housing (27G).
Heat transmission housing (27G) in area of bearing seat of ball bearing (36) and then
mount transmission housing (27G).
SPECIAL TOOL Assembly stand		 Fig 5
    SPECIAL TOOL Collet chuck Fig 3
    SPECIAL TOOL Puller Fig 7
    SPECIAL TOOL Assembly device Fig 9
27 Remove park pawl lift solenoid (L21) for park pawl actuator (100). If required. AR27.19-P-0012MFC 
28 Remove parking lock mechanism. If required. AR27.60-P-0950MFC
29 Disassemble power output shaft (60). If required. AR27.50-P-0560MFC
30 Disassemble power output shaft (80). If required. AR27.50-P-0560MFC
31 Disassemble drive shaft (30). If required. AR27.50-P-0550MFC
32 Remove differential (50) and the bearing. If required. AR27.50-P-0771MFC
33 Disassemble hollow shaft (40). If required. AR27.50-P-0650MFC
34 Disassemble clutch housing (27K). If required. AR27.40-P-0520MFC
35 Disassemble transmission housing (27G). If required. AR27.40-P-0510MFC
36 Adjust gear set of dual-clutch transmission. If new parts are installed. AR27.50-P-0900MFC
37 Clean power output shaft (60), power output shaft (80), differential (50), hollow shaft (40), drive shaft (30) and the associated bearing shells. Assembly cleaner *BR00.45-Z-1028-04A 
38 Clean sealing surfaces on clutch housing (27K) and transmission housing (27G).   AR01.00-P-0050-01A
  Notes on application of flange sealants to seal major assemblies NOTES
Do not use any sharp-edged tools or
abrasive paper.
The sealing surfaces can be damaged
otherwise.
NOTES
Ensure that no dirt particle enters the
transmission.
Even the smallest dirt particles in the
hydraulic components will lead to
malfunctions and total failure of the
transmission.		 AH00.00-P-0500-01MNE
    Loctite 7200 *BR00.45-Z-1038-04A 
    Loctite 7063 (400 ml) cleaning spray *BR00.45-Z-1046-04A 
39 Assemble in the reverse order.    
INSTALLING Install     
40 Remove transmission from assembly stand.   AR27.10-P-0600-01NKB 
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars IMPORTANTCommercially available devices/tools 
Workshop crane		 WS01.00-P-0262B
    SPECIAL TOOL Adapter Fig 6
    SPECIAL TOOL Assembly device Fig 2
    SPECIAL TOOL Assembly device Fig 9
41 Install transmission.   AR27.10-P-0009MFC 
AUTOMATIC TRANSMISSION COMPLETE

Number Designation Transmission 724.0
BA27.10-P-1001-04F Bolt, clutch housing to transmission housing M6 Nm 8
M8 Stage 1 Nm 10
Stage 2 ∠° 90
AUTOMATIC TRANSMISSION COMPLETE

Number Designation Transmission 724.0
BA27.10-P-1008-04F Nut (left-hand thread), oil pump gear to oil pump Stage 1 Nm 10
Stage 2 ∠° 180
AUTOMATIC TRANSMISSION COMPLETE

Number Designation Transmission 724.0
BA27.10-P-1009-04F Nut, hollow shaft rotor to oil pump Nm 7
AUTOMATIC TRANSMISSION COMPLETE

Number Designation Transmission 724.0
BA27.10-P-1010-04F Bolt, permanent magnet to reset piston Nm 5
Fig 1: Identifying Puller (724 589 01 33 00)
G16063327Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Assembly Device (724 589 02 40 00)
G10250350Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Collet Chuck (168 589 00 34 00)
G16063329Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Application Gun (112 589 00 25 00)
G11065567Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Assembly Stand (000 588 00 31 00)
G12816466Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Adapter (724 589 04 31 00)
G15491520Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Puller (001 589 49 33 00)
G15491558Courtesy of MERCEDES-BENZ USA
Fig 8: Identifying Pliers (000 589 52 37 00)
G11972023Courtesy of MERCEDES-BENZ USA
Fig 9: Identifying Assembly Device (724 589 00 40 00)
G16063335Courtesy of MERCEDES-BENZ USA
Fig 10: Identifying Puller (724 589 02 33 00)
G15489032Courtesy of MERCEDES-BENZ USA
Fig 11: Identifying Drift Set (724 589 00 15 00)
G16063337Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1013-01A Sealant, Loctite 5970, 50 ml A 003 989 98 20 10
BR00.45-Z-1028-04A Assembly cleaner A 000 986 56 01
BR00.45-Z-1038-04A Loctite 7200 A 010 989 90 71
BR00.45-Z-1046-04A Loctite 7063 (400 ml) cleaning spray A 001 986 71 71 09
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