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Remove/install transmission with torque converter - AR27.10-P-0500EV

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TRANSMISSION 722.9 (except 722.96) in MODEL 212 

TRANSMISSION 722.9 (except 722.96) in MODEL 218 

MODIFICATION NOTES

24.2.14 "Remove corrosion from crankshaft" added Operation step 32  
Fig 1: Transmission With Torque Converter Remove/Install Components - Shown On Model 212.072 (1 Of 3)
G09975676Courtesy of MERCEDES-BENZ USA

Shown on model 212.072 

Fig 2: Transmission With Torque Converter Remove/Install Components - Shown On Model 212.072 (2 Of 3)
G09975677Courtesy of MERCEDES-BENZ USA
Fig 3: Transmission With Torque Converter Remove/Install Components - Shown On Model 212.072 (3 Of 3)
G09975678DANGERNOTESNOTESNOTESREMOVINGINSTALLINGTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONINSTALLATION IMPORTANTTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONIMPORTANTTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONNOTESTORQUE SPECIFICATIONTORQUE SPECIFICATIONSPECIAL TOOLSPECIAL TOOLNOTESNOTESIMPORTANTSPECIAL TOOLSPECIAL TOOLNOTESNOTESTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONIMPORTANTNOTESIMPORTANTINSTALLATION IMPORTANTTORQUE SPECIFICATIONINSTALLATION IMPORTANTSPECIAL TOOLSPECIAL TOOLINSPECTREFER TO SELF-DIAGNOSTIC SYSTEMSDANGERCourtesy of MERCEDES-BENZ USA
DANGER 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
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
NOTES Notes on bolted connections with self tapping screws   AH00.00-P-0007-01SF
NOTES Information on preventing damage to electronic components due to electrostatic discharge   AH54.00-P-0001-01A
REMOVINGINSTALLING Remove/install     
1 Disconnect battery ground line   AR54.10-P-0003EW
2 Secure vehicle on vehicle lift   AR00.60-P-0100EWS
3.1 Remove engine compartment paneling Vehicles with gasoline engine  
3.2 Remove bottom sections of soundproofing Vehicles with diesel engine  
AR94.30-P-5300EW
4 Remove vacuum line for brake systems TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 272.983  
AR43.10-P-0355EW
5 Remove air duct housing TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 272.983  
AR09.20-P-0080EW
6 Remove left exhaust line from catalytic converter TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 272.983  
AR14.20-P-1020-01EWD
TORQUE SPECIFICATION Bolt, automatic transmission to engine *BA27.40-P-1008-01A 
TORQUE SPECIFICATION Bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner *BA49.10-P-1040-01AE 
TORQUE SPECIFICATION Bolt, clamp for exhaust gas recirculation line to catalytic converter *BA49.10-P-1041-01AE 
7 Detach right exhaust line from catalytic converter TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 272.983  
AR14.20-P-1020-01EWD
TORQUE SPECIFICATION Bolt, automatic transmission to engine *BA27.40-P-1008-01A 
TORQUE SPECIFICATION Bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner *BA49.10-P-1040-01AE 
TORQUE SPECIFICATION Bolt, clamp for exhaust gas recirculation line to catalytic converter *BA49.10-P-1041-01AE 
8 Disconnect electrical connectors of heated oxygen sensors and unclip from brackets TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 271
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 273
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 276.9
TRANSMISSION 722.9 (except 722.96) in MODEL 212, 218 with ENGINE 278
TRANSMISSION 722.9 (except 722.96) in MODEL 218 with ENGINE 276		  
9 Remove electrical connector brackets from transmission (5) TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 271
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 273
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 276.9
TRANSMISSION 722.9 (except 722.96) in MODEL 212, 218 with ENGINE 278
TRANSMISSION 722.9 (except 722.96) in MODEL 218 with ENGINE 276		  
TORQUE SPECIFICATION Bolt/nut, exhaust bracket to exhaust *BA49.10-P-1024-01AE 
10 Detach ground line (2) from transmission (5) TORQUE SPECIFICATION Bolt, ground line to transmission housing *BA27.40-P-1013-01A 
11.1 Detach catalytic converters from exhaust manifold TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 272.983  
TORQUE SPECIFICATION Screw/bolt, catalytic converter to exhaust manifold *BA49.10-P-1001-01AE 
11.2 Detach exhaust pipe downstream of catalytic converter TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 274
INSTALLATION IMPORTANT Install a new seal and clamp.		  
TORQUE SPECIFICATION Nut, clamp for CAT to front exhaust system *BA49.10-P-1045-01AE 
11.3 Remove bolts (14) and place bracket (15) to one side TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 276.8  
TORQUE SPECIFICATION Bolt of exhaust bracket to transmission *BA49.10-P-1023-01AE 
TORQUE SPECIFICATION Bolt/nut, exhaust bracket to exhaust *BA49.10-P-1024-01AE 
12 Detach bracket for diesel particulate filter from oil pan TRANSMISSION 722.9 (except 722.96) in MODEL 212, 218 with ENGINE 642  
TORQUE SPECIFICATION Bolt, diesel particulate filter bracket to oil pan *BA49.10-P-1008-01AE 
TORQUE SPECIFICATION Bolt/nut, bracket of diesel particulate filter to lower diesel particulate filter *BA49.10-P-1009-01AE 
13 Remove clamp on diesel particulate filter TRANSMISSION 722.9 (except 722.96) in MODEL 212, 218 with ENGINE 642  
TORQUE SPECIFICATION Bolt, clamp securing connecting pipe to diesel particulate filter *BA49.10-P-1020-01AE 
14 Remove heat shield (1) and disconnect electrical connector from transmission control   AR27.40-P-0700-01EW 
TORQUE SPECIFICATION Bolt, heat shield to transmission housing *BA27.40-P-1014-01A 
15 Set DIRECT SELECT gear selector switch to position "N" and release parking brake    
16 Detach electrical line (3) from intelligent servo module for DIRECT SELECT (A80)    
17 Disconnect electrical connector (12) from electric transmission oil pump (M42) IMPORTANT To do so, unclip the retaining clips from the transmission (5) and create access to the electrical line (13).  
18.1 Remove bolts (17) and place bracket (16) to one side TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 156
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 271
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 273
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 274
TRANSMISSION 722.9 (except 722.96) in MODEL 212, 218 with ENGINE 276.9
TRANSMISSION 722.9 (except 722.96) in MODEL 212, 218 with ENGINE 278
TRANSMISSION 722.9 (except 722.96) in MODEL 212.074/092/274/292, 218.974/992		  
18.2 Remove nuts (11) and place bracket (10) to one side TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 276.8  
19 Remove bolts (18) and place brackets (19, 21) to one side TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 276.8  
TORQUE SPECIFICATION Bolt, bracket to transmission *BA49.10-P-1011-01AE 
20 Remove left and right brackets (4) TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 271
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 273
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 276.9
TRANSMISSION 722.9 (except 722.96) in MODEL 212, 218 with ENGINE 278
TRANSMISSION 722.9 (except 722.96) in MODEL 218 with ENGINE 276		  
TORQUE SPECIFICATION Bolt of exhaust bracket to transmission *BA49.10-P-1023-01AE 
TORQUE SPECIFICATION Bolt/nut, exhaust bracket to exhaust *BA49.10-P-1024-01AE 
21 Detach torque converter (9) or start-up clutch from driver spider and pry off driver spider uniformly using long wedge TRANSMISSION 722.9 (except 722.93/96) in MODEL 212, 218 AR27.20-P-0100-01A 
TRANSMISSION 722.93 in MODEL 212, 218
NOTES Do not use an impact wrench or compressed air tool.
The threaded unions of the driver spider can otherwise be damaged.		 AR27.51-P-0400-01W
TORQUE SPECIFICATION
TRANSMISSION 722.9 (except 722.93/96) in MODEL 212, 218		 *BA27.20-P-1002-01C 
TORQUE SPECIFICATION
TRANSMISSION 722.93 in MODEL 212, 218		 *BA27.51-P-1001-01A 
SPECIAL TOOL Socket wrench bit Figure
SPECIAL TOOL Long wedge Figure
22 Detach oil lines from transmission (5) and oil pan and place to one side TRANSMISSION 722.995 in MODEL 212 with ENGINE 274.9
without CODE 924 (Provision for natural gas operation)		 AR27.55-P-0600MR
TRANSMISSION 722.9 (except 722.96/97) in MODEL 218
TRANSMISSION 722.9 (except 722.96/97/995) in MODEL 212
NOTES Before starting work the area around the oil lines must be thoroughly cleaned in the area around the separation points on the transmission (5).
Even the smallest dirt particles in the hydraulic components can lead to malfunctions and a total failure of the transmission (5).
NOTES Do not bend or kink oil cooling lines. Otherwise the hydraulic system could fail or the transmission (5) could get damaged.
IMPORTANT Seal off the connections on the transmission (5) and the oil lines using SPECIAL TOOL stop plugs.		 AR27.55-P-0600EV
SPECIAL TOOL Record plug Fig 8
23 Support transmission (5) Transmission jack
Transmission platform		  
24 Remove rear engine crossmember (7a) and rear engine mount (7b) TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 157
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 271
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 273
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 274
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 276
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 278
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 642
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 651
TRANSMISSION 722.9 (except 722.96) in MODEL 218 with ENGINE 157
TRANSMISSION 722.9 (except 722.96) in MODEL 218 with ENGINE 276
TRANSMISSION 722.9 (except 722.96) in MODEL 218 with ENGINE 278
TRANSMISSION 722.9 (except 722.96) in MODEL 218 with ENGINE 642
TRANSMISSION 722.9 (except 722.96) in MODEL 218 with ENGINE 651		 AR22.10-P-1180CW
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 156 AR22.10-P-1180CMG
25 Mark propeller shaft NOTES Mark the propeller shaft so that it can be installed again at the installation position used by the plant.
Otherwise, drivetrain vibrations will occur.		  
26 Mark vibration damper TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 272.983
NOTES Mark the vibration damper so that it can be installed again at the installation position used by the plant.
Otherwise, drivetrain vibrations will occur.		  
27 Remove front flexible coupling (20v)   AR41.10-P-0050EW
28 Release right exhaust line from exhaust gas recirculation actuator motor TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 272.983  
AR14.20-P-1020-01EWD
TORQUE SPECIFICATION Bolt, automatic transmission to engine *BA27.40-P-1008-01A 
TORQUE SPECIFICATION Bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner *BA49.10-P-1040-01AE 
TORQUE SPECIFICATION Bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner *BA49.10-P-1040-01AE 
29 Remove starter from transmission (5) TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 156 AR15.30-P-7100CMG
TRANSMISSION 722.9 (except 722.96) in MODEL 212, 218 with ENGINE 157
TRANSMISSION 722.9 (except 722.96) in MODEL 212.073/273, 218.373/973 with ENGINE 278		 AR15.30-P-7100ELB
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 271 AR15.30-P-7100CW
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 273		 AR15.30-P-7100EW
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 274.9
with CODE 924 (Provision for natural gas operation)		 AR15.30-P-7100MRC
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 274
without CODE 924 (Provision for natural gas operation)		 AR15.30-P-7100MR
TRANSMISSION 722.9 (except 722.96) in MODEL 212, 218 with ENGINE 276 AR15.30-P-7100EL
TRANSMISSION 722.9 (except 722.96) in MODEL 212, 218 with ENGINE 642 AR15.30-P-7100SXI
TRANSMISSION 722.9 (except 722.96) in MODEL 212, 218 with ENGINE 651
IMPORTANT Remove bracket of right exhaust line and place starter to the side with lines connected and secure to prevent it falling down.		 AR15.30-P-7100CD
30 Remove bolts (8) and remove transmission (5) downwards NOTES The engine must be propped up at the oil pan when the transmission (5) is removed. Otherwise the engine can tip over and damage will be caused.
IMPORTANT Secure torque converter (9) or start-up clutch against falling down.
INSTALLATION IMPORTANT Align the bores of the torque converter (9) or start-up clutch with the threaded unions in the driver spider.		  
TORQUE SPECIFICATION Bolt, automatic transmission to engine *BA27.40-P-1008-01A 
31 Remove torque converter (9) or start-up clutch TRANSMISSION 722.9 (except 722.93/96) in MODEL 212, 218 AR27.20-P-0500-01W 
TRANSMISSION 722.93 in MODEL 212, 218
INSTALLATION IMPORTANT Grease crankshaft bearing journals with multipurpose paste.		 AR27.51-P-0400-02AMG
TRANSMISSION 722.9 (except 722.93/96) in MODEL 212, 218 *BE27.20-P-1001-01E 
TRANSMISSION 722.93 in MODEL 212, 218 *BE27.51-P-1001-02A 
Multi-purpose paste *BR00.45-Z-1009-06A 
SPECIAL TOOL Handles Figure
SPECIAL TOOL Parallel rest Figure
32 Remove corrosion from crankshaft   AR03.20-P-1000-01A
Assembly cleaner *BR00.45-Z-1028-04A 
Multi-purpose paste *BR00.45-Z-1009-06A 
INSPECT Check     
33 Check threaded unions in driver spider If threaded unions are damaged or loose:
↓
Install a new driver spider.		  
TRANSMISSION 722.9 in MODEL 212 with ENGINE 156 AR03.30-P-8001CMG
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 157
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 276
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 278
TRANSMISSION 722.9 (except 722.96) in MODEL 218 with ENGINE 157
TRANSMISSION 722.9 (except 722.96) in MODEL 218 with ENGINE 276
TRANSMISSION 722.9 (except 722.96) in MODEL 218 with ENGINE 278		 AR03.30-P-8001EL
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 271 AR03.30-P-8001CW
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 (except 722.96) in MODEL 212 with ENGINE 273		 AR03.30-P-8001EW
TRANSMISSION 722.9 (except 722.96) in MODEL 212, 218 with ENGINE 642 AR03.30-P-8001SXI
TRANSMISSION 722.9 (except 722.96) in MODEL 212, 218 with ENGINE 651 AR03.30-P-8001CD
34 Install in the reverse order    
35 Check transmission oil level and correct if necessary   AR27.00-P-0270W 
36 Read out fault memory using diagnostic system and clear if necessary    
REFER TO SELF-DIAGNOSTIC SYSTEMS AD00.00-P-2000-04A
37 Perform transmission adaptation using diagnostic system After replacement or repair of transmission (5)  
38 Reset service life data of torque converter lockup clutch using diagnostic system After replacing torque converter (9)  
DANGER 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. 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
39 Perform engine test run and check transmission (5) for function and leaks
TEST VALUES FOR TORQUE CONVERTER

Number Designation TRANSMISSION 722.9
BE27.20-P-1001-01E Installed height of torque converter Distance, bolt flange to transmission housing flange Helical screwed connection mm 9, 5
See picture AR27.20-P-0500-01W 
Axial screwed connection mm 19, 5
TEST VALUES FOR START UP CLUTCH

Number Designation TRANSMISSION 722.93
BE27.51-P-1001-02A Installed height of start up clutch Distance, bolt flange to transmission housing flange mm 9, 5
- -
TORQUE CONVERTER

Number Designation TRANSMISSION 722.9
BA27.20-P-1002-01C Bolt, torque converter to drive plate Straight threaded connection M8 Nm 42
Angled threaded connection Stage 1 Nm 4
Stage 2 Nm 30
Stage 3 ∠° 90
HOUSING

Number Designation TRANSMISSION 722.9
BA27.40-P-1008-01A Bolt, automatic transmission to engine M10X40 Nm 38
M10X45 Nm 38
M10X90 Nm 38
M12 Nm -
HOUSING

Number Designation TRANSMISSION 722.9
BA27.40-P-1013-01A Bolt, ground line to transmission housing Nm 9
HOUSING

Number Designation TRANSMISSION 722.9
BA27.40-P-1014-01A Bolt, heat shield to transmission housing Nm 9
START UP CLUTCH

Number Designation TRANSMISSION 722.93
BA27.51-P-1001-01A Bolt, start up clutch to driver Stage 1 Nm 4
Stage 2 Nm 30
Stage 3 ∠° 90
EXHAUST SYSTEM

Number Designation ENGINE 156, 157, 271, 272, 273, 276, 278 in MODEL 212
BA49.10-P-1001-01AE Screw/bolt, catalytic converter to exhaust manifold Nm 20
EXHAUST SYSTEM

Number Designation ENGINE 642, 651 in MODEL 212 ENGINE 642, 651 in MODEL 218
BA49.10-P-1008-01AE Bolt, diesel particulate filter bracket to oil pan Nm 20 20
EXHAUST SYSTEM

Number Designation ENGINE 642, 651 in MODEL 212 ENGINE 642, 651 in MODEL 218
BA49.10-P-1009-01AE Bolt/nut, bracket of diesel particulate filter to lower diesel particulate filter Nm 20 20
EXHAUST SYSTEM

Number Designation ENGINE 156, 157, 271, 272, 273, 276, 278 in MODEL 212
BA49.10-P-1011-01AE Bolt, bracket to transmission Nm 39
EXHAUST SYSTEM

Number Designation ENGINE 642, 651 in MODEL 212 ENGINE 642, 651 in MODEL 218
BA49.10-P-1020-01AE Bolt, clamp securing connecting pipe to diesel particulate filter Nm 35 35
EXHAUST SYSTEM

Number Designation ENGINE 156, 157, 271, 272, 273, 276, 278 in MODEL 212 ENGINE 157, 276, 278 in MODEL 218
BA49.10-P-1023-01AE Bolt of exhaust bracket to transmission Nm 20 20
EXHAUST SYSTEM

Number Designation ENGINE 156, 157, 271, 272, 273, 276, 278 in MODEL 212 ENGINE 157, 276, 278 in MODEL 218
BA49.10-P-1024-01AE Bolt/nut, exhaust bracket to exhaust Nm 20 20
EXHAUST SYSTEM

Number Designation ENGINE 156, 157, 271, 272, 273, 276, 278 in MODEL 212
BA49.10-P-1040-01AE Bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner Nm 9
EXHAUST SYSTEM

Number Designation ENGINE 156, 157, 271, 272, 273, 276, 278 in MODEL 212
BA49.10-P-1041-01AE Bolt, clamp for exhaust gas recirculation line to catalytic converter Nm 9
EXHAUST SYSTEM

Number Designation ENGINE 274 in MODEL 212
BA49.10-P-1045-01AE Nut, clamp for CAT to front exhaust system Nm 22
Fig 4: Identifying Long Wedge (115 589 03 59 00)
G09975679Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Parallel Rest (126 589 04 31 00)
G09975680Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Handles (168 589 00 62 00)
G09975681Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Socket Wrench Bit (001 589 65 09 00)
G09975682Courtesy of MERCEDES-BENZ USA
Fig 8: Identifying Record Plug (129 589 00 91 00)
G09975683Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1009-06A Multi-purpose paste A 000 989 80 51 10
BR00.45-Z-1028-04A Assembly cleaner Adolf Wurth GmbH & Co. KG
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