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Disassemble, assemble and seal - AR28.10-P-1004EW

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MODEL 212, 218 with TRANSMISSION 722.96/97 

MODIFICATION NOTES

15.5.14 gear to split driveshaft screw   BA28.10-P-1003-01F
Fig 1: Automatic Transmission Components (1 Of 2)
G09975992Courtesy of MERCEDES-BENZ USA
Fig 2: Automatic Transmission Components (2 Of 2)
G09975993Courtesy of MERCEDES-BENZ USA
Fig 3: Automatic Transmission & Radial Shaft Sealing Ring
G09975994Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
IMPORTANT General information on repair work on transmission   AH27.00-P-1000-01A
1 Move DIRECT SELECT gear selector switch to "N" position    
2 Detach ground line from battery   AR54.10-P-0003EW
NOTES Notes on battery   AH54.10-P-0001-01A
3 Secure vehicle on vehicle lift   AR00.60-P-0100EWS
4.1 Remove right catalytic converter MODEL 212 with ENGINE 272 with TRANSMISSION 722.96
MODEL 212 with ENGINE 273 with TRANSMISSION 722.96		  
AR49.10-P-7100EW
4.2 Remove diesel particulate filter MODEL 212 with ENGINE 642 with TRANSMISSION 722.96
MODEL 212 with ENGINE 651 with TRANSMISSION 722.96
MODEL 218 with ENGINE 642 with TRANSMISSION 722.96		  
MODEL 212 with ENGINE 642 with TRANSMISSION 722.96
MODEL 212 with ENGINE 651 with TRANSMISSION 722.96		 AR49.10-P-7100EWI
MODEL 218 with ENGINE 642 with TRANSMISSION 722.96 AR14.40-P-1000OGE
4.3 Remove rear part of exhaust system MODEL 212 with ENGINE 157 with TRANSMISSION 722.96/97
MODEL 212, 218 with ENGINE 276 with TRANSMISSION 722.96
MODEL 212, 218 with ENGINE 278 with TRANSMISSION 722.96
MODEL 218 with ENGINE 157 with TRANSMISSION 722.97		  
AR49.10-P-7100EL
5 Support automatic transmission (5) with transmission jack and transmission platform Transmission jack
Transmission platform		  
6 Remove rear engine crossmember Model 212, 218 AR22.10-P-1180CW
NOTES Notes on bolted connections with self tapping screws   AH00.00-P-0007-01SF
7 Detach flexible coupling from transfer case (24) and propeller shaft   AR41.10-P-0050EW
8 Lower the automatic transmission (5)    
9 Remove front axle gear propeller shaft MODEL 212, 218 with TRANSMISSION 722.97
MODEL 212.08/09/28/29, 218.39/99 with TRANSMISSION 722.96
When replacing the radial shaft sealing ring (20) or during repair work on the automatic transmission (5)		  
AR41.10-P-0070EWX
10 Remove heat shields on the vehicle underbody in the area of the transfer case (24)    
11 Detach stiffening bridge on underfloor TORQUE SPECIFICATION Bolt, front reinforcement brace to frame floor assembly *BA61.10-P-1002-01H 
TORQUE SPECIFICATION Bolt, rear reinforcement brace to frame floor assembly *BA61.10-P-1003-01H 
12 Drain oil out of transfer case (24); to do so, remove oil drain screw (23) from intermediate housing (4) INSTALLATION IMPORTANT Replace seal.  
TORQUE SPECIFICATION
MODEL 212, 218 with TRANSMISSION 722.96		 *BA28.10-P-1006-01E 
TORQUE SPECIFICATION
MODEL 212, 218 with TRANSMISSION 722.97		 *BA28.10-P-1006-01F 
13 Remove intelligent servo module (ISM) Only to remove the ring gear (14).  
AR27.19-P-0550EW
DISASSEMBLINGASSEMBLING Disassemble/assemble     
14 Detach collar nut (1) from output flange (2) INSTALLATION IMPORTANT Replace collar nut (1) and secure after tightening.  
TORQUE SPECIFICATION
MODEL 212, 218 with TRANSMISSION 722.96		 *BA28.10-P-1004-01E 
TORQUE SPECIFICATION
MODEL 212, 218 with TRANSMISSION 722.97		 *BA28.10-P-1004-01F 
SPECIAL TOOL Pin wrench Fig 4
SPECIAL TOOL Socket wrench bit Fig 5
SPECIAL TOOL Adapter Fig 8
15 Detach output flange (2) from output shaft (11) IMPORTANT Check output flange (2) for wear and damage and replace if necessary.
IMPORTANT Use puller if output flange (2) is seized.		  
SPECIAL TOOL Puller Fig 9
16 Remove radial shaft sealing ring (3) from rear cover (9) In the event of leakage or when replacing the grooved ball bearing (7).
NOTES
Do not damage the seat of the radial shaft sealing ring (3).
Leaks may otherwise occur.
INSTALLATION IMPORTANT Use drift to pound in new radial shaft sealing ring (3) until it abuts with the rear cover (9).		  
SPECIAL TOOL Drift
Check seat of radial shaft sealing ring (3) for wear and damage; in case of complaints,
↓
replace rear cover (9).		 Fig 13
17 Remove rear cover (9); to do this, unscrew bolts (8) and remove rear cover (9) INSTALLATION NOTES
The sealing surfaces on intermediate housing (4) and rear cover (9) must be free of oil and grease.
This prevents leaks occurring.		  
TORQUE SPECIFICATION
MODEL 212, 218 with TRANSMISSION 722.96		 *BA28.10-P-1002-01E 
TORQUE SPECIFICATION
MODEL 212, 218 with TRANSMISSION 722.97		 *BA28.10-P-1002-01F 
Loctite 7200 *BR00.45-Z-1038-04A 
Loctite 5970 sealant *BR00.45-Z-1013-01A 
18 Remove grooved ball bearing (7); to do this, remove retaining ring (6) from rear cover (9) and press out grooved ball bearing (7) IMPORTANT The grooved ball bearing (7) only has to be replaced in the event of complaints or damage.  
19 Remove retaining ring (10) and remove output shaft (11) INSTALLATION IMPORTANT Check retaining ring (10) for correct seat in planet carrier (16).
Check retaining ring (10) for deformation and damage, if necessary:
↓
replace retaining ring (10).		  
20 Using the assembly tool move the automatic transmission (5) into position "P" at the range selector shaft When removing the ring gear (14).  
SPECIAL TOOL Assembly tool Fig 11
21 Detach needle roller bearing (15) from ring gear (14) Check needle roller bearing (15) for wear and damage; if necessary,
↓
replace needle roller bearing (15).		  
22 Remove connecting bolt (13) INSTALLATION IMPORTANT Connecting bolt (13) must always be replaced.  
TORQUE SPECIFICATION
MODEL 212, 218 with TRANSMISSION 722.96		 *BA28.10-P-1003-01E 
TORQUE SPECIFICATION
MODEL 212, 218 with TRANSMISSION 722.97		 *BA28.10-P-1003-01F 
23 Remove annulus gear (14) using pulling device   AR28.10-P-1001-02SYZ 
IMPORTANT Pay attention to correct seat of pulling device on annulus gear (14).
INSTALLATION IMPORTANT Press on ring gear (14) by hand and pull in using new connecting bolt (13).		  
SPECIAL TOOL Extraction tool Figure
24 Remove planet carrier (16)    
25 Remove bolts (17) and remove intermediate housing (4) INSTALLATION NOTES
Sealing surfaces on intermediate housing (4) and automatic transmission (5) must be free of oil and grease.
This prevents leaks occurring.
INSTALLATION IMPORTANT Assembly sleeve must be removed from differential side gear (19) before attaching the intermediate housing (4).		  
TORQUE SPECIFICATION
MODEL 212, 218 with TRANSMISSION 722.96		 *BA28.10-P-1001-01E 
TORQUE SPECIFICATION
MODEL 212, 218 with TRANSMISSION 722.97		 *BA28.10-P-1001-01F 
Loctite 7200 *BR00.45-Z-1038-04A 
Loctite 5970 sealant *BR00.45-Z-1013-01A 
26 Remove differential side gear (19) INSTALLATION NOTES
Assembly sleeve must be used when installing differential side gear (19).
This prevents the radial shaft sealing ring (20) of the differential side gear (19) from being damaged in the transmission housing.
INSTALLATION IMPORTANT Pay attention to the correct seat of assembly sleeve on differential side gear (19).		  
SPECIAL TOOL Assembly sleeve Fig 10
27 Remove drive pinion (18)    
28 Remove radial shaft sealing ring (20) of differential side gear (19) using a suitable tool NOTES
Do not support tool for prying off radial shaft sealing ring (20) from the automatic transmission (5) without using a rag.
The sealing surface on the automatic transmission (5) could otherwise be damaged (see picture 3, refer to Fig 3).
INSTALLATION IMPORTANT Replace radial shaft sealing ring (20) and make sure that it is installed in the correct position (see enlarged detail in picture 3, refer to Fig 3).
INSTALLATION IMPORTANT Pound radial shaft sealing ring (20) into transmission housing using drift. Make sure that the radial shaft sealing ring (20) is seated correctly in the automatic transmission (5).		  
SPECIAL TOOL Drift Fig 12
29 Remove pilot bushing (22) and shim (21) from output shaft (11) The basic dimension must be determined before repair work on the automatic transmission (5):
↓		  
Measure end play between park pawl gear and grooved ball bearing AR27.50-P-0600-06SYZ
End play between park pawl gear and grooved ball bearing *BE27.50-P-1004-01A 
Loctite 7200 *BR00.45-Z-1038-04A 
Loctite 7063 cleaning spray (150 ml) *BR00.45-Z-1046-04A 
SPECIAL TOOL Parallel rest Fig 7
30 Assemble in the reverse order    
CLEANING Clean     
31 Clean all parts of the transfer case (24) thoroughly Assembly cleaner *BR00.45-Z-1028-04A 
32 Install in the reverse order    
33 Prefill transfer case (24) with a prefill quantity of 0.7 l transmission oil and fill automatic transmission (5) with transmission oil The transfer case (24) is connected to the oil circuit of the automatic transmission (5). The oil level can therefore only be checked and corrected via the automatic transmission (5):
↓		  
Filling automatic transmission with fluid AR27.00-P-0270SYZ
TORQUE SPECIFICATION
MODEL 212, 218 with TRANSMISSION 722.96		 *BA28.10-P-1005-01E 
TORQUE SPECIFICATION
MODEL 212, 218 with TRANSMISSION 722.97		 *BA28.10-P-1005-01F 
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
34 Test run engine and check the automatic transmission (5) and transfer case (24) for leaktightness and function
CHECK VALUES FOR GEAR SET

Number Designation TRANSMISSION 722.9
BE27.50-P-1004-01A End play between park pawl gear and grooved ball bearing mm 0, 20...0, 40
COMPLETE TRANSFER CASE

Number Designation MODEL 204, 205, 207, 212, 216, 217, 218, 221, 222 with TRANSMISSION 722.96
BA28.10-P-1001-01E Bolt, intermediate housing to transmission housing Nm 20
COMPLETE TRANSFER CASE

Number Designation TRANSMISSION 722.97 in MODEL 212, 217, 218, 222
BA28.10-P-1001-01F Bolt, intermediate housing to transmission housing Nm 20
COMPLETE TRANSFER CASE

Number Designation MODEL 204, 205, 207, 212, 216, 217, 218, 221, 222 with TRANSMISSION 722.96
BA28.10-P-1002-01E Bolt, transmission cover to intermediate housing Nm 8
COMPLETE TRANSFER CASE

Number Designation TRANSMISSION 722.97 in MODEL 212, 217, 218, 222
BA28.10-P-1002-01F Bolt, transmission cover to intermediate housing Nm 8
COMPLETE TRANSFER CASE

Number Designation MODEL 204, 205, 207, 212, 216, 217, 218, 221, 222 with TRANSMISSION 722.96
BA28.10-P-1003-01E Bolt, ring gear to two-part output shaft Stage 1 Nm 30
Stage 2 ∠° 180
COMPLETE TRANSFER CASE

Number Designation TRANSMISSION 722.97 in MODEL 212, 217, 218, 222
BA28.10-P-1003-01F Bolt, ring gear to two-part output shaft Stage 1   Nm 30
Stage 2 Loosen   -
Stage 3   Nm 5
COMPLETE TRANSFER CASE

Number Designation MODEL 204, 205, 207, 212, 216, 217, 218, 221, 222 with TRANSMISSION 722.96
BA28.10-P-1004-01E Collar nut, output flange to output shaft Nm 200
COMPLETE TRANSFER CASE

Number Designation TRANSMISSION 722.97 in MODEL 212, 217, 218, 222
BA28.10-P-1004-01F Collar nut, output flange to output shaft Nm 200
COMPLETE TRANSFER CASE

Number Designation MODEL 204, 205, 207, 212, 216, 217, 218, 221, 222 with TRANSMISSION 722.96
BA28.10-P-1005-01E Filling screw to intermediate housing Nm 20
COMPLETE TRANSFER CASE

Number Designation TRANSMISSION 722.97 in MODEL 212, 217, 218, 222
BA28.10-P-1005-01F Filling screw to intermediate housing Nm 20
COMPLETE TRANSFER CASE

Number Designation MODEL 204, 205, 207, 212, 216, 217, 218, 221, 222 with TRANSMISSION 722.96
BA28.10-P-1006-01E Drain screw to intermediate housing Nm 30
COMPLETE TRANSFER CASE

Number Designation TRANSMISSION 722.97 in MODEL 212, 217, 218, 222
BA28.10-P-1006-01F Drain screw to intermediate housing Nm 30
FRAME FLOOR ASSEMBLY

Number Designation MODEL 212 MODEL 218
BA61.10-P-1002-01H Bolt, front reinforcement brace to frame floor assembly Nm 30 30
FRAME FLOOR ASSEMBLY

Number Designation MODEL 212 MODEL 218
BA61.10-P-1003-01H Bolt, rear reinforcement brace to frame floor assembly Nm 24 24
Fig 4: Identifying Pin Wrench (129 589 01 07 00)
G09975995Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Socket Wrench Bit (126 589 02 09 00)
G09975996Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Extraction Tool (722 589 01 33 00)
G09975997Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Parallel Rest Tool (126 589 04 31 00)
G09975998Courtesy of MERCEDES-BENZ USA
Fig 8: Identifying Adapter (100 589 02 59 00)
G09975999Courtesy of MERCEDES-BENZ USA
Fig 9: Identifying Puller (124 589 04 33 00)
G09976000Courtesy of MERCEDES-BENZ USA
Fig 10: Identifying Assembly Sleeve (722 589 06 14 00)
G09976001Courtesy of MERCEDES-BENZ USA
Fig 11: Identifying Assembly Tool (722 589 03 09 00)
G09976002Courtesy of MERCEDES-BENZ USA
Fig 12: Identifying Drift (722 589 14 15 00)
G09976003Courtesy of MERCEDES-BENZ USA
Fig 13: Identifying Drift (140 589 12 15 00)
G09976004Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1013-01A Loctite 5970 sealant A 003 989 98 20
BR00.45-Z-1028-04A Assembly cleaner Adolf Wurth GmbH & Co. KG
BR00.45-Z-1038-04A Loctite 7200 Henkel Loctite Deutschland GmbH
BR00.45-Z-1046-04A Loctite 7063 cleaning spray (150 ml) A 001 986 71 71 10
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