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

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Transmission 724.1 in model 118, 177, 247 

G16140705Courtesy of MERCEDES-BENZ USA

Shown on transmission 724.1 with code M005 (Vehicles with 4-MATIC/all-wheel drive) 

G16140706Courtesy of MERCEDES-BENZ USA

Shown on transmission 724.1 without code ME08 (Hybrid drive 75-84 KW VARIANT (INCLUDING PLUGIN)) 

G16140707Courtesy of MERCEDES-BENZ USA
G16140708Courtesy of MERCEDES-BENZ USA
G16140709Courtesy of MERCEDES-BENZ USA
G16140710Courtesy of MERCEDES-BENZ USA
G16140711Courtesy of MERCEDES-BENZ USA
G16140712Courtesy of MERCEDES-BENZ USA
DANGER Risk of death  when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC) Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.
Transmission 724.1 in model 177, 247 with code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))		 AS00.00-Z-0035-01A
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. AS00.00-Z-0017-01A
    Deburr repair panels.  
Notice    Transmission 724.1 in model 177, 247 with code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN)) AH00.00-Z-0300-01A
Notice    Transmission 724.1 in model 177.086/186, 247.086
with code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))		 AH08.10-P-0001-01MRD
Notice      AH00.00-P-5000-01A
Notice    Transmission 724.1 in model 177, 247 with code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN)) AH54.00-P-0004-01RFW
Notice      AH00.00-P-0020-01A
  Notes on automatic transmission   AH27.19-P-0001-01NKB 
  Notes on application of flange sealants to seal major assemblies   AH00.00-P-0500-01MNE
REMOVING Remove     
1 Remove dual-clutch transmission.   AR27.10-P-0009MFA 
2 Secure dual-clutch transmission to assembly stand.   AR27.10-P-0600-01MFA 
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars   WS01.00-P-0262B
    IMPORTANT Commercially available devices/tools Workshop crane  
    SPECIAL TOOL Assembly device Fig 8
DISASSEMBLING Disassemble     
3.1 Detach power take-off (4) from clutch housing (27K). Transmission 724.1 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 
3.2 Remove drive unit. Transmission 724.120 in model 177, 247 with engine 282
with code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))		  
      AR08.10-P-0019MFH
4 Remove oil pan (5).   AR27.10-P-7032MFA 
5 Remove dual clutch transmission fully integrated transmission control electrohydraulic controller unit (Y3/14).   AR27.19-P-0200MFA 
6 Remove park pawl actuator.   AR27.60-P-0951MFA
7 Remove screws (12) and detach guide tube for ultrasound measurement (13) from transmission housing (27G).    
8 Remove dual clutch.   AR27.20-P-0070MFA 
9 Remove retaining ring (6) from oil pump gear (7). SPECIAL TOOL Pliers Fig 7
10 Remove oil pump gear (7) with chain (8) and drive gear (9).    
11 Remove retaining ring (10) from drive shaft (30). SPECIAL TOOL Pliers Fig 7
12 Remove screws (11).    
13 Attach support fixture (027K) to assembly device (027). IMPORTANT Aid of helper required.  
    IMPORTANTSPECIAL TOOL Slide on support fixture (027K) far enough until it engages audibly.
Grease spindle with multipurpose grease.		  
    MB multipurpose grease, 400 g *BR00.45-Z-1017-06A 
    SPECIAL TOOL Assembly device Fig 8
    SPECIAL TOOL Support fixture Fig 10
14 Turn down transmission support (027A) far enough until it makes contact with clutch housing (27K). SPECIAL TOOL Support fixture Fig 10
15 Turn clamped dual-clutch transmission with assembly stand through 180°.    
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars   WS01.00-P-0262B
16 Unscrew screws (14) and remove housing support (027G) of assembly device (027) from transmission housing (27G). SPECIAL TOOL Assembly device Fig 8
17 Remove cap (15) from transmission housing (27G) using a suitable tool. IMPORTANT The cap (15) is irreparably damaged during removal.  
18 Release shaft package retaining rings (3) using spreader tools (01, 02, 03).   AR27.10-P-0510-02MFA 
    SPECIAL TOOL Spreader Fig 2
19 Pry transmission housing (27G) off clutch housing (27K) by applying a suitable tool at cutouts and remove.    
20 Remove spreader tools (01, 02, 03) from transmission housing (27G). NOTES
SPECIAL TOOL Attach and detach spreader tool (01, 02, 03) only when detensioned.
Otherwise the transmission housing (27G) will be damaged.		  
    SPECIAL TOOL Spreader Fig 2
21 Remove sealant from coupling housing (27K) and transmission housing (27G).   AR01.00-P-0050-01A
    NOTES
Do not use any sharp-edged tools or abrasive paper.
The sealing surfaces can be damaged otherwise.		  
    Loctite 7063 (400 ml) cleaning spray *BR00.45-Z-1046-04A 
    Loctite 7200 *BR00.45-Z-1038-04A 
22 Disassemble transmission housing (27G). If required.  
      AR27.40-P-0510MFA
23 Remove dual clutch oil duct seal (16).    
24 Unscrew screw (17) and remove oil pipe (18).    
25 Unscrew screws (19) and remove oil pipe (20).    
26 Check oil pipe (18) and oil pipe (20) for damage. If the oil pipe (18) or the oil pipe (20) is damaged,
↓
replace oil pipe (18) or oil pipe (20).		  
27 Position assembly device (027W) on assembly device (027) and shafts.   AR27.10-P-0600-01MFA 
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars   WS01.00-P-0262B
    IMPORTANT Aid of helper required.  
    IMPORTANTCommercially available devices/tools 
Workshop crane
IMPORTANT Make sure that the SPECIAL TOOL assembly device (027W) is positioned correctly on the shafts and gearshifts (60S, 80S).		  
    SPECIAL TOOL Assembly device Fig 8
    SPECIAL TOOL Assembly device Fig 4
28 Turn clamped dual-clutch transmission with assembly stand through 180°.    
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars   WS01.00-P-0262B
29 Remove support fixture (027K) from assembly device (027). IMPORTANT Aid of helper required.  
    SPECIAL TOOL Support fixture Fig 10
    SPECIAL TOOL Assembly device Fig 8
30 Attach extraction and insertion tool (027B) to clutch housing (27K). IMPORTANT Transmission 724.1 in model 118, 177, 247 with engine 139
Transmission 724.1 in model 118, 177, 247 with engine 260
Transmission 724.1 in model 118, 177, 247 with engine 654
To do so, secure at position no. 1 (A) using screws (21).
IMPORTANT Transmission 724.1 in model 118, 177, 247 with engine 282
except code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))
To do so, secure at position no. 2 (B) using screws (21).		  
    IMPORTANT Transmission 724.1 in model 118, 177, 247 with engine 282
with code ME08 (Hybrid drive 75-84 kW
VARIANT (INCLUDING PLUGIN))
If a third position is present, also secure using screws (21).		  
    SPECIAL TOOL Extraction and insertion tool Fig 5
31 Position sleeve (027C) of extraction and insertion tool (027B) on drive shaft (30). SPECIAL TOOL Extraction and insertion tool Fig 5
32 Screw in thread (027D) of extraction and insertion tool (027B) and release clutch housing (27K) from shafts and gearshifts (60S 80S). IMPORTANT Ensure that the gearshifts (60S, 80S) do not become jammed in the clutch housing (27K). If necessary, hold the gearshifts (60S 80S) securely when detaching the clutch housing (27K).  
    SPECIAL TOOL Extraction and insertion tool Fig 5
33 Detach extraction and insertion tool (027B) from clutch housing (27K). SPECIAL TOOL Extraction and insertion tool Fig 5
34 Remove sleeve (027C) from drive shaft (30) SPECIAL TOOL Extraction and insertion tool Fig 5
35 Remove clutch housing (27K) from output shaft (60), output shaft (80), differential (50), hollow shaft (40), drive shaft (30) and gearshifts (60S, 80S).    
36 Disassemble coupling housing (27K). If required.  
      AR27.40-P-0520MFA
37 Slide output shaft (60), output shaft (80), differential (50), hollow shaft (40), drive shaft (30) and gearshifts (60S, 80S) apart. If required.  
      AR27.10-P-0600-01MFA 
    IMPORTANT To do so, pull the locking pin upward and slide the mount of the SPECIAL TOOL assembly device (027W) outward.  
    SPECIAL TOOL Assembly device Fig 4
    SPECIAL TOOL Assembly device Fig 8
38 Remove differential (50) and tapered roller bearings. If required.  
      AR27.50-P-0771MFA
39 Clean output shaft (60), output shaft (80), differential (50), hollow shaft (40), drive shaft (30) and the associated bearing shells. Assembly cleaner *BR00.45-Z-1028-04A 
40 Clean sealing surfaces on coupling housing (27K) and transmission housing (27G).   AR01.00-P-0050-01A
    NOTES Do not use any sharp-edged tools or abrasive paper.
The sealing surfaces can be damaged otherwise.
NOTES Ensure that no dirt particles fall into the dual-clutch transmission.
Even the smallest of dirt particles in the hydraulic components impair the function of the dual-clutch transmission and lead to failure.		  
    Loctite 7200 *BR00.45-Z-1038-04A 
    Loctite 7063 (400 ml) cleaning spray *BR00.45-Z-1046-04A 
ASSEMBLING Assemble     
41 Install differential (50) and tapered roller bearings. If differential (50) was removed.  
      AR27.50-P-0771MFA
42 Remove hollow shaft (40) and remove needle bearing (31) from drive shaft (30).    
43 Position spacer (027E) on drive shaft (30) and reattach hollow shaft (40). NOTES Always remove needle bearing (31) during assembly.
Otherwise the needle bearing (31) will be damaged.		  
    SPECIAL TOOL Spacer Fig 3
44 Slide output shaft (60), output shaft (80), If required.  
  differential (50), hollow shaft (40), drive shaft (30) and gearshifts (60s, 80s) together. IMPORTANT Make sure that output shaft (60), output shaft (80), differential (50), hollow shaft (40), drive shaft (30) and gearshifts (60s, 80s) are engaged.
If the gearwheels do not mesh,
turn height adjustment screw (32) slightly upward.		  
45 Assemble clutch housing (27K). If clutch housing (27K) has been disassembled.  
      AR27.40-P-0520MFA
46 Position clutch housing (27K) on output shaft (60), output shaft (80), differential (50), hollow shaft (40), drive shaft (30) and gearshifts (60s, 80s).    
47 Position thrust piece (027F) of support fixture (027K) on drive shaft (30). IMPORTANT Thrust piece (027F) of
SPECIAL TOOL support fixture (027K).		  
    SPECIAL TOOL Support fixture Fig 10
48 Attach support fixture (027K) to assembly device
(027).		 IMPORTANT Aid of helper required.  
    SPECIAL TOOL Support fixture Fig 10
    SPECIAL TOOL Assembly device Fig 8
49 Turn height adjustment screw (32) of drive shaft (30) on assembly device (027W) all the way up. IMPORTANT Otherwise the retaining ring (10) cannot be installed.  
    SPECIAL TOOL Assembly device Fig 4
50 Pull clutch housing (27K) onto output shaft (60), output shaft (80), differential (50), hollow shaft (40), drive shaft (30) and gearshifts (60s, 80s). IMPORTANT Make sure that the transmission mount (027A) engages correctly in the thrust piece (027F).
Make sure that the gearshifts (60s, 80s) engage correctly in the clutch housing (27K).
Press on until the retaining ring (10) can be installed.		  
    SPECIAL TOOL Support fixture Fig 10
51 Detension support fixture (027K) and remove+ from assembly device (027). IMPORTANT Aid of helper required.  
    SPECIAL TOOL Support fixture Fig 10
    SPECIAL TOOL Assembly device Fig 8
52 Remove thrust piece (027F) of support fixture (027K) from drive shaft (30). SPECIAL TOOL Support fixture Fig 10
53 Install retaining ring (10) on drive shaft (30). IMPORTANT Replace retaining ring (10).  
    SPECIAL TOOL Pliers Fig 7
54 Attach support fixture (027K) to assembly device (027) and position transmission mount (027A) on clutch housing (27K). IMPORTANT Aid of helper required.
IMPORTANT Slide on support fixture (027K) far enough until it engages audibly.		  
    SPECIAL TOOL Support fixture Fig 10
    SPECIAL TOOL Assembly device Fig 8
55 Turn clamped dual-clutch transmission with assembly stand through 180°.    
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars   WS01.00-P-0262B
56 Detach assembly device (027W) from assembly device (027) and output shaft (60), output shaft (80), differential (50), hollow shaft (40), drive shaft (30).    
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars   WS01.00-P-0262B
    SPECIAL TOOL Assembly device Fig 4
    SPECIAL TOOL Assembly device Fig 8
57 Remove drive shaft (30) and spacer (027E). SPECIAL TOOL Spacer Fig 3
58 Slide needle bearing (31) onto drive shaft (30) and insert drive shaft (30) together with needle bearing (31) into hollow shaft (40).    
59 Install oil pipe (20) and screw in screws (19). TORQUE SPECIFICATION Screw, oil pipe to center section of oil pipe *BA27.10-P-1011-06C 
60 Install oil pipe (18) and screw in screw (17). TORQUE SPECIFICATION Screw, oil pipe to coupling housing *BA27.10-P-1012-06C 
61 Install dual clutch oil duct seal (16). IMPORTANT Replace dual clutch oil duct seal (16).  
62 Install shaft package retaining rings (3). IMPORTANT Replace shaft package retaining rings (3).  
63 Assemble transmission housing (27G). If transmission housing (27G) has been disassembled.  
      AR27.40-P-0510MFA
64 Release shaft package retaining rings (3) using spreader tools (01, 02, 03).   AR27.10-P-0510-02MFA 
    SPECIAL TOOL Spreader Fig 2
65 Apply sealing compound to sealing surface of clutch housing (27K).    
REFER TO BASIC KNOWLEDGE Coupling housing sealant path   GF27.40-P-0001-01MFA 
    IMPORTANT Observe sealant path.  
    Sealant, Loctite 5970, 50 ml *BR00.45-Z-1013-01A 
    SPECIAL TOOL Application gun Fig 1
66 Attach transmission housing (27G) to clutch housing (27K).    
67 Attach housing support (027G) to transmission housing (27G) and tighten with screws (14). SPECIAL TOOL Assembly device Fig 8
68 Turn clamped dual-clutch transmission with assembly stand through 180°.    
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars   WS01.00-P-0262B
    IMPORTANT The shafts engage audibly in the shaft package retaining rings (3).  
69 Remove support fixture (027K) from assembly device (027). IMPORTANT Aid of helper required.  
    SPECIAL TOOL Support fixture Fig 10
    SPECIAL TOOL Assembly device Fig 8
70 Screw in screws (11). IMPORTANT Remove excess sealing compound.  
    Loctite 7063 (400 ml) cleaning spray *BR00.45-Z-1046-04A 
    TORQUE SPECIFICATION Bolt, clutch housing to transmission housing *BA27.10-P-1002-06C 
71 Turn clamped dual-clutch transmission with assembly stand through 180°.    
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars   WS01.00-P-0262B
72 Remove spreader tools (01, 02, 03) from transmission housing (27G). NOTES
SPECIAL TOOL Attach and detach spreader tool (01, 02, 03) only when detensioned.
Otherwise the transmission housing (27G) will be damaged.		  
    SPECIAL TOOL Spreader Fig 2
73 Check whether output shaft (60), output shaft (80) and drive shaft (30) are engaged in the shaft package retaining rings (3). IMPORTANT Perform visual inspection through openings
in transmission housing (27G).		  
74 Press the caps (15) into the transmission housing (27G) using a drift. IMPORTANT Replace caps (15).  
    SPECIAL TOOL Handle Fig 9
    SPECIAL TOOL Drift Fig 6
75 Install guide tube for ultrasound measurement (13) and tighten screws (12). IMPORTANT Replace guide tube for ultrasound measurement (13).  
    TORQUE SPECIFICATION Overflow pipe to transmission housing *BA27.10-P-1007-06C 
76 Turn clamped dual-clutch transmission with assembly stand through 180°.    
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars   WS01.00-P-0262B
77 Install oil pump gear (7) with chain (8) and drive gear (9).    
78 Install retaining ring (6) at oil pump gear (7). IMPORTANT all new retaining ring (6).  
    SPECIAL TOOL Pliers Fig 7
79 Install dual clutch.   AR27.20-P-0070MFA 
80 Install park pawl actuator.   AR27.60-P-0951MFA
81 Install dual-clutch transmission fully integrated transmission control electrohydraulic controller unit (Y3/14).   AR27.19-P-0200MFA 
82 Install oil pan (5).   AR27.10-P-7032MFA 
83.1 Attach power take-off (4) to clutch housing (27K). Transmission 724.1 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 
    TORQUE SPECIFICATION Bolt, transmission housing to power take-off *BA27.19-P-1006-01E 
    TORQUE SPECIFICATION Screw/bolt, power take-off to coupling housing *BA27.19-P-1007-01E 
83.2 Install drive unit. Transmission 724.120 in model 177, 247 with engine 282
with code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))		  
      AR08.10-P-0019MFH
INSTALLING Install     
84 Remove dual-clutch transmission from assembly stand.    
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars   WS01.00-P-0262B
    IMPORTANT Commercially available devices/tools
Workshop crane		  
    SPECIAL TOOL Assembly device Fig 8
85 Install dual-clutch transmission.   AR27.10-P-0009MFA 
AUTOMATIC TRANSMISSION COMPLETE

Number Designation Transmission 724.1
BA27.10-P-1002-06C Bolt, clutch housing to transmission housing M8 Stage 1 Nm 10
Stage 2 ∠° 90
AUTOMATIC TRANSMISSION COMPLETE

Number Designation Transmission 724.1
BA27.10-P-1007-06C Overflow pipe to transmission housing Nm 8
AUTOMATIC TRANSMISSION COMPLETE

Number Designation Transmission 724.1
BA27.10-P-1011-06C Screw, oil pipe to center section of oil pipe Nm 8
AUTOMATIC TRANSMISSION COMPLETE

Number Designation Transmission 724.1
BA27.10-P-1012-06C Screw, oil pipe to coupling housing Nm 8
ELECTROHYDRAULIC CONTROLLER UNIT

Number Designation Transmission 724.1
BA27.19-P-1006-01E Bolt, transmission housing to power take-off M8 Nm 29
ELECTROHYDRAULIC CONTROLLER UNIT

Number Designation Transmission 724.1
BA27.19-P-1007-01E Screw/bolt, power take-off to coupling housing M8 Nm 29
Fig 1: Identifying Application Gun (112 589 00 25 00)
G16140713Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Spreader (724 589 00 37 00)
G16140714Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Spacer (724 589 00 34 00)
G16140715Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Assembly Device (724 589 06 40 00)
G16140716Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Extraction And Insertion Tool (724 589 00 43 00)
G16140717Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Drift (724 589 05 15 00)
G16140718Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Pliers (000 589 52 37 00)
G16140719Courtesy of MERCEDES-BENZ USA
Fig 8: Identifying Assembly Device (724 589 05 40 00)
G16140720Courtesy of MERCEDES-BENZ USA
Fig 9: Identifying Handle (001 589 00 40 00)
G16140721Courtesy of MERCEDES-BENZ USA
Fig 10: Identifying Support Fixture (724 589 07 31 00)
G16140722Courtesy 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-1017-06A MB multipurpose grease, 400 g A 001 989 34 51 11
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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