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Remove/install, disassemble/assemble intermediate housing - AR27.40-P-0500EH

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TRANSMISSION 724.2 

MODIFICATION NOTES

10.9.14 "Insert guide pins (24) facing each other into the electrical machine housing (4)" added. Operation step 16.1  
12.9.14 Screw guide pins facing each other into the intermediate housing (1) added. Operation step 16.2  
Fig 1: Intermediate Housing Remove/Install Components (1 Of 4)
G09975752Courtesy of MERCEDES-BENZ USA
Fig 2: Intermediate Housing Remove/Install Components (2 Of 4)
G09975753Courtesy of MERCEDES-BENZ USA
Fig 3: Intermediate Housing Remove/Install Components (3 Of 4)
G09975754Courtesy of MERCEDES-BENZ USA
Fig 4: Intermediate Housing Remove/Install Components (4 Of 4)
G09975755Courtesy of MERCEDES-BENZ USA
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
IMPORTANT Notes on automatic transmission   AH27.19-P-0001-01NKB
REMOVING Remove     
1 Remove transmission TRANSMISSION 724.2 in MODEL 205 with ENGINE 651 AR27.10-P-0502RFH
TRANSMISSION 724.2 in MODEL 222 with ENGINE 651 AR27.10-P-0502LFY
TRANSMISSION 724.2 in MODEL 222 with ENGINE 276 AR27.10-P-0502LFH
TRANSMISSION 724.2 in MODEL 212.095/195 with ENGINE 276.9
TRANSMISSION 724.2 in MODEL 212.098/298 with ENGINE 651.9		 AR27.10-P-0502EH 
2 Fasten transmission on assembly stand   AR27.10-P-0600-01EH 
SPECIAL TOOL Assembly device Figure
SPECIAL TOOL Lifting device Figure
3 Remove screws/bolts (2) IMPORTANT Total of 11 screws/bolts (2) present.  
4 Carefully release intermediate housing (1) from electrical machine housing (4) using a plastic mallet and assembly wedge and remove NOTES Do not pry off the intermediate housing (1) using a sharp-edged tool.
The sealing surfaces can be damaged otherwise.
IMPORTANT Secure pilot bushing (5) against falling down.		  
SPECIAL TOOL Mounting wedge Fig 6
DISASSEMBLINGASSEMBLING Disassemble/assemble     
5 Remove fit bolt (6) and bolts (7) NOTES Carefully unfasten and tighten fit bolt (6) and bolts (7).
The coils of the electrical machine rotor position sensor (L20) can otherwise be damaged.
NOTESAssembly:  Do not mix up the fit bolt (6) and bolts (7). Correct operation of the electrical machine rotor position sensor (L20) can otherwise not be guaranteed.
IMPORTANTAssembly:  Install a new fit bolt (6) and new bolts (7).		  
TORQUE SPECIFICATION Bolt, turning angle sensor to intermediate flange *BA27.10-P-1017-04G 
6 Unscrew screws/bolts (8) and remove retaining clamp (9) IMPORTANTAssembly:  Replace bolts (8).  
TORQUE SPECIFICATION Bolt, turning angle sensor to intermediate flange *BA27.10-P-1017-04G 
7 Remove electrical machine rotor position sensor (L20) IMPORTANT Check position sensor for electrical machine rotor (L20) for damage.  
8 Unclip bracket (10) at catch hooks (22) from connector (23) of electrical machine rotor position sensor (L20) When replacing the electrical machine rotor position sensor (L20).
IMPORTANTAssembly:  Pay attention to the installation position of the electrical lines of the electrical machine rotor position sensor (L20).
Make sure that the plug (23) is seated correctly in the tabs of the bracket (10) (arrows A).		  
9 Remove thrust bearing (12) IMPORTANTAssembly:  Check thrust bearing (12) for wear and damage.  
10 Unscrew screws/bolts (13) and remove oil pump (11) from intermediate housing (1) IMPORTANTAssembly:  Install new bolts (13).
IMPORTANTAssembly:  Line up holes for oil pump (11) with hole pattern for threaded connection.		  
TORQUE SPECIFICATION Bolt, oil pump to intermediate housing *BA27.10-P-1016-04G 
11 Unscrew screws/bolts (15) and remove oil displacer (14) from intermediate housing (1) TORQUE SPECIFICATION Bolt, oil displacer to intermediate flange *BA27.10-P-1018-04G 
12 Unscrew screws/bolts (17) and remove locking plate (16) from intermediate housing (1) TORQUE SPECIFICATION Bolt, locking plate to intermediate flange *BA27.10-P-1019-04G 
13 Check sealing plate (19) for damage NOTESAssembly: 
Do not apply any sealant to the sealing plate (19).
Otherwise leakage is not possible.
NOTESAssembly: 
The sealing plate (19) must not be bent and must not exhibit any scratches, kinks or any other damage.
Otherwise leakage is not possible.
If damage is present:
↓
Replace sealing plate (19).		  
14 Assemble in the reverse order    
INSTALLING Install     
15 Remove radial shaft sealing ring (18)   AR27.40-P-0300EH 
16.1 Insert guide pins (24) facing each other into the electrical machine housing (4) TRANSMISSION 724.2
with CODE ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN)) TRANSMISSION 724.2
with CODE ME06 (Hybrid drive 50-KW variant (incl. plugin))		  
SPECIAL TOOL Guide bolts Fig 5
16.2 Screw guide pins (24) facing each other into the intermediate housing (1). TRANSMISSION 724.2
with CODE ME04 (Mild hybrid drive)		  
SPECIAL TOOL Guide bolts Fig 9
17 Place intermediate housing (1) onto housing for electrical machine (4) NOTES When positioning the intermediate housing (1), pay attention to the routing of the interlock lines (20).
The interlock lines (20) will otherwise be pinched which will cause damage.
IMPORTANT When positioning the intermediate housing (1), turn the drive shaft (21) so that the drivers (arrows B) of the oil pump (11) engage in the notches (arrows C) on the drive shaft (21). Secure pilot bushing (5) against falling down.		  
18 Fully tighten bolts (2) TORQUE SPECIFICATION Bolt, intermediate flange to clutch housing *BA27.10-P-1002-04G 
19 Install radial shaft sealing ring (18)   AR27.40-P-0300EH 
IMPORTANT Replace radial shaft sealing ring (18).
20 Detach transmission from assembly device SPECIAL TOOL Assembly device Figure
SPECIAL TOOL Lifting device Figure
21 Install transmission TRANSMISSION 724.2 in MODEL 205 with ENGINE 651 AR27.10-P-0502RFH
TRANSMISSION 724.2 in MODEL 222 with ENGINE 651 AR27.10-P-0502LFY
TRANSMISSION 724.2 in MODEL 222 with ENGINE 276.9 AR27.10-P-0502LFH
TRANSMISSION 724.2 in MODEL 212.095/195 with ENGINE 276.9
TRANSMISSION 724.2 in MODEL 212.098/298 with ENGINE 651.9		 AR27.10-P-0502EH 
22 Connect diagnostic system and perform sensor rotor adaptation When replacing electrical machine rotor position sensor (L20)  
REFER TO SELF-DIAGNOSTIC SYSTEMS TRANSMISSION 724.2 in MODEL 205, 222 AD00.00-P-2000-04B
REFER TO SELF-DIAGNOSTIC SYSTEMS TRANSMISSION 724.2 in MODEL 212 AD00.00-P-2000-04A
COMPLETE AUTOMATIC TRANSMISSION

Number Designation TRANSMISSION 724.2
BA27.10-P-1002-04G Bolt, intermediate flange to clutch housing Nm 9
COMPLETE AUTOMATIC TRANSMISSION

Number Designation TRANSMISSION 724.2
BA27.10-P-1016-04G Bolt, oil pump to intermediate housing Nm 20
COMPLETE AUTOMATIC TRANSMISSION

Number Designation TRANSMISSION 724.2
BA27.10-P-1017-04G Bolt, turning angle sensor to intermediate flange Nm 9
COMPLETE AUTOMATIC TRANSMISSION

Number Designation TRANSMISSION 724.2
BA27.10-P-1018-04G Bolt, oil displacer to intermediate flange Nm 9
COMPLETE AUTOMATIC TRANSMISSION

Number Designation TRANSMISSION 724.2
BA27.10-P-1019-04G Bolt, locking plate to intermediate flange Nm 9
Fig 5: Identifying Guide Bolts (724 589 04 15 00)
G09975756Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Mounting Wedge (110 589 03 59 00)
G09975757Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Lifting Device (724 589 02 63 00)
G09975758Courtesy of MERCEDES-BENZ USA
Fig 8: Identifying Assembly Device (724 589 04 40 00)
G09975759Courtesy of MERCEDES-BENZ USA
Fig 9: Identifying Guide Bolts (724 589 01 15 00)
G09975760Courtesy of MERCEDES-BENZ USA
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