Testing Repair

1999 Mercedes-Benz SLK230
1998-2004 TRANSMISSION Automatic Transmission - Testing & Repair - 170 Chassis
1998-2004 TRANSMISSION
Automatic Transmission - Testing & Repair - 170 Chassis
TESTING & REPAIR

INSPECT ATF LEVEL IN AUTOMATIC TRANSMISSION, ADD ATF IF NECESSARY - AR27.00-P-
0101A
Transmission 722.6 in MODELS 129, 140, 163, 170, 202, 208, 210, 211, 215, 220, 230, 240
Transmission 722.6 in MODEL 461, 463 (except, 463.270 /271)
Fig. 1: Identifying ATF Level Components
Adding transmission oil

Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not grasp hot or
burns during starting rotating parts.
procedure or when
working near the running
engine
1 Drive vehicle to level
surface
2 Open engine hood
3 Remove locking pin Remove locking pin
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Friday, October 30, 2009 8:52:35
8:52:29 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
(93a) by breaking off the plate

of the locking pin (93a)
with a suitable tool and
pressing out the pin
remaining in the cap (93)
downwards.
4 Remove cap (93) from oil
filler pipe
5 Fill with transmission oil After a complete refill
and after changing the
transmission oil, pour in
approx. 5 liters of
transmission oil before
starting the engine.
Insufficient and excessive
quantities of oil result in
malfunctions and
transmission damage.
*BF27.00-P-1001-01C
Fig. 2
Fig. 4
6 Start engine and allow it
to idle in drive position
"P"
7 Fill with remaining Initial charge
quantity of transmission
oil
8 Apply service brake and
shift through drive
positions several times
with vehicle stationary
and engine running at idle
speed
9 Insert oil dipstick all When the transmission
the way into oil filler is cold (approx. 25 °C),
pipe, pull it out again and the transmission oil level
read off transmission oil must be between the
level "min" and "max" mark of
the marking (A). The
exact transmission oil
level can only be
determined at a
transmission oil
temperature of 80 °C.
Fig. 3
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Friday, October 30, 2009 8:52:30 AM Page 2 © 2005 Mitchell Repair Information Company, LLC.
10 Warm up transmission oil

to operating temperature
Check transmission
fluid level
11 Apply service brake and
shift through drive
positions several times
with vehicle stationary
and engine running at idle
speed
12 Connect STAR Wait for 2 minutes
DIAGNOSIS and check until the exact
transmission oil transmission oil
temperature in drive temperature can be
position "D" measured.
Operate service brakes
at the same time. The
exact transmission oil
level can only be
determined at a
transmission oil
temperature of 80 °C.
STAR DIAGNOSIS *WH58.30-Z-1048-13A
diagnosis system
13 Insert oil dipstick all If too much
the way into the oil filler transmission oil is added,
pipe, pull out again, read it is absolutely essential
off transmission oil level to drain off or extract the
and correct if necessary surplus. Insufficient and
excessive quantities of oil
result in malfunctions and
transmission damage.
The transmission oil
level must be between the
"min" and "max" mark of
the marking (B).
Fig. 3
Fig. 5
14 Check transmission oil After filling with
level again transmission oil
15 Mount cap (93) on oil
filler pipe and press in
new locking pin (93a)
until it latches
16 Perform engine test run
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and, with engine running,

check transmission for
leaks and that it is
functioning correctly
Automatic transmission
Number Designation Transmission Transmission Transmission
722.600/601/604/605/ 722.602/603/615 722.610/638
606/607/608/609/611/
613/614/616/617/618/
629/634/639/660/661/
662/664/665/689/695/
696/699
For new filling
BF27.00- Filling Initial charge Liters 7.5 (+0.5) 7,0 (+0,5) 8.0
P-1001- capacity Oil change Liters - - -
01C Specifications Sheet BB00.40-P-0236-10A BB00.40-P-0236- BB00.40-P-
for Operating 10A 0236-10A
Fluids Sheet BB00.40-P-0236-12A BB00.40-P-0236- BB00.40-P-
12A 0236-12A
Number Designation Transmission Transmission 722.620/621
722.620/621 in in model 140,
model 129 transmission 722.622/623/
624/625/626/627/628/
630/631/632/633/635/
636/663/666/669
For new filling
BF27.00-P- Filling Initial charge Liters 8,2 (+0,5) 8,6 (+0,5)
1001-01C capacity Oil change Liters - -
Specifications for Sheet BB00.40-P-0236- BB00.40-P-0236-10A
Operating Fluids 10A
Sheet BB00.40-P-0236- BB00.40-P-0236-12A
12A
Number Designation Transmissions Transmission Transmission
722.640/644 722.640/64472 722.667/668/67
2/676/690
For new filling
BF27.00- Filling Initial charge Liters 7.5 7,3 (+0,5) 9
01C Specifications Sheet BB00.40-P-0236- BB00.40-P- BB00.40-P-0236-
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for Operating 10A 0236-10A 10A

Fluids Sheet BB00.40-P-0236- BB00.40-P- BB00.40-P-0236-
12A 0236-12A 12A
Number Designation Transmission 722.637 in Transmission Transmission
model 722.637 in 722.649
461.302/331/332 /342//345 model
463.322/323
For new filling
BF27.00- Filling Initial charge Liters 7.9 7.9 7.5
01C Specifications Sheet BB00.40-P-0236-10A BB00.40-P- BB00.40-P-
for Operating 0236-10A 0236-10A
Fluids Sheet BB00.40-P-0236-12A BB00.40-P- BB00.40-P-
0236-12A 0236-12A
Number Designation Transmission Transmission
722.673 in model 722.674 in model
163 163
For new filling
BF27.00-P- Filling Initial charge Liters 7,6-8,0 8,8-9,2
1001-01C capacity Oil change Liters - -
Specifications for Sheet BB00.40-P-0236- BB00.40-P-0236-
Operating Fluids 12A 12A
- -
Sheet
722.641 in 722.612/697/ 722.612/ in
model 170 698 in model model 202
202
For new filling
BF27.00- Filling Initial charge Liters 7,3-7,7 7,3-7,7 8,5-8,9
01C Specifications Sheet BB00.40-P- BB00.40-P- BB00.40-P-
for Operating 0236-12A 0236-12A 0236-12A
Fluids Sheet - -
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Fig. 2: Identifying Funnel (126 589 12 63 00)
Fig. 3: Identifying Dipstick (140 589 15 21 00)
Fig. 4: Identifying Filling Pipe (140 589 49 63 00)
Fig. 5: Identifying Hand Pump (210 589 00 71 00)
Commercially available tools

Number Designation
WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis 6511 1801 00
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system, Compact Passenger Car
REMOVE/INSTALL TRANSMISSION WITH TORQUE CONVERTER - AR27.10-P-0500B
TRANSMISSION 722.6 in MODELS 129, 140, 170, 202, 208, 210
Fig. 6: Identifying Transmission With Torque Converter Components
Modification notes
13.1.06 Oil drain screw to torque Transmission 722.6 *BA27.20-P-1001-01C
converter
Bolt, torque converter to Transmission 722.6 *BA27.20-P-1002-01C
drive plate
Remove/install
Notes on self- AH00.00-N-0001-
locking nuts and 01A
bolts
Before starting the
work the area
around the oil
cooling lines (49)
must be thoroughly
cleaned in the area
around the
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separation points on
the transmission.
Even the smallest
dirt particles,
introduced into the
hydraulic
components, can
lead to malfunctions
and a total failure of
the transmission
1 Disconnect ground Insulate ground line as a protection
cable of battery against unintentional contact of
detached ground line with ground point
of battery.
Model 129, 170, 202, 208, 210 AR54.10-P-0003A
Model 140 ra54001400003x
Notes on battery AH54.10-P-0001-
01A
2.1 Detach oil filler pipe Model 129, 140 with ENGINE 119 AR27.10-P-0500-04A
(61) from engine Model 202, 210 with engines 111, 604,
605, 606
2.2 Remove oil filler Models 129, 140 with engine 120 AR27.10-P-0500-04A
pipe (61) Model 210 with engine 119
3 Unscrew oil drain *BA27.10-P-1001-
screw (4) from If the transmission oil is burnt or 03A
transmission oil pan interspersed with abrasive particles, the
and drain oil cooler lines (49) and oil cooler must
transmission oil be flushed out: ?
Flush oil cooler and oil cooling lines AR27.55-P-0001A
4 Remove oil drain *BA27.20-P-1001-
screw (9) from If the transmission oil pan contains 01C
torque converter and metal shavings, drain the transmission
drain transmission fluid from the torque converter via the
oil drain hole through a clean cloth.
If the cloth contains metal swarf after
draining the transmission oil, it is then
necessary to replace the torque
converter.
In case of doubt, flush the torque
converter with ATF only.
Metal shavings can damage the
transmission at a later stage.
Oil drain screw (9) Transmission 722.6 BT27.20-P-0001-01A
on torque converter
discontinued
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5.1 Remove shield (62) Shield (62) no longer required on model AR27.10-P-0500-01A
and detach 13-pin 129 with engine 119 and engine 120 as
plug (26) of 03.96
6 Detach control Transmission models AR27.60-P-0500-05A
cable / gears for 722.620 up to end no. 0001680
parking lock 722.621 up to end no. 0001976
interlock (80) from 722.622 up to end no. 0016286
transmission
Transmission models AR27.60-P-0500-05B
722.60/61/63/66/69
722.620 as of end no. 0001681
722.621 as of end no. 0001977
722.622 as of end no. 0016287
722.623/624/625/627/628/629
For installing and removing, move
the selector lever or range selector lever
(33) in position "P" and leave in
position "P" when cable/transmission is
removed.
Installation: Check function of
parking shift lock (80).
7.1 Detach retaining Model 210 4MATIC AR46.20-P-0600A
plate for rack-and- See: ?
pinion steering Remove/install rack-and-pinion steering
8 Remove cover (81) *BA27.20-P-1002-
and remove bolts 01C
(95) from torque
converter
9 Detach left and right
oil cooling line (49)
from transmission
10 Remove shift rod Pliers Fig. 8
(63); to do this
remove securing
clips with pliers
Installation: Adjust shift rod (63). AR27.60-P-0980B
11 Remove exhaust
bracket (64).
12.1 Detach exhaust Model 129, 140, 210 with ENGINE 119
system (94) at rear
with V-belt
12.2 Remove exhaust Models 129, 140 with engine 120 AR49.10-P-7000F
system (94) as from
connector
13 Remove fan shroud Model 210 with engine 119
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from radiator Model 140 with engine 606

14 Remove engine Engine 112, 113 AR22.10-P-1160HV
support with rear
engine mount (65)
Engine 119 ra22001192120x
Engine 120 AR22.10-P-1160AO
Model 202, 210 with engines 111, 604, AR22.10-P-1160HB
605, 606
Model 202, 210 with engines 611, 612, AR22.10-P-1160HC
613
15 Detach front *BA41.10-P-1001-
propeller shaft (66) 01A
16.1 Detach propeller Model 210 4MATIC *BA33.30-P-1003-
shaft from transfer 02A
case
17 Detach ground strap
(46) from
transmission
18 Unscrew Secure torque converter to prevent it
transmission from from falling out.
crankcase and
remove downwards
at an angle using
transmission
platform
*WE58.40-Z-1018-
11A
19.1 Remove torque If necessary AR27.20-P-0500-01B
converter using Installation: Grease the torque
grab handles converter lightly on drive flange.
Multi-purpose paste *BR00.45-Z-1009-
06A
Fig. 7
20 Install in the reverse
order
21 Check oil level in AR27.00-P-0101A
transmission and
correct if necessary
22 Read out fault STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-
memory with STAR 13A
DIAGNOSIS and
erase if necessary.
23.1 Perform After replacing or repairing
transmission transmission, perform transmission
adaptation adaptation.
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Risk of accident Secure vehicle to prevent it from AS00.00-Z-0005-01A

24 caused by vehicle moving by itself.
starting off by itself Wear closed and snug-fitting work
when engine is clothes.
running. Risk of Do not touch hot or rotating parts.
injury caused by
contusions and
burns during starting
procedure or when
working near the
engine as it is
running
Perform engine test
run and check
transmission for
leaks and that it is
Torque converter
Number Designation Transmission 722.6
except 722.648
BA27.20-P- Oil drain screw M8 Nm 10
1001-01C to torque
converter M10 Nm 15
BA27.20-P- Bolt, torque Straight Nm 42
1002-01C converter to threaded
drive plate connection
Helical cut Stage 1 Nm 4
Stage 2 Nm 30
Stage 3 Angle° 90
Oil pan, automatic transmission

except 722.628/648/649
BA27.10-P-1001-03A Oil drain screw on oil Nm 20
pan
Front axle shaft

Number Designation Model 210.08/28
BA33.30-P-1003-02A Bolt, front axle gear Nm 30
propeller shaft to transfer
case flange
Driveshaft
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Number Designation Model 129 Model 140 Model 170

BA41.10-P- Self-locking nut of M10 Nm 40 - 40
1001-01A flexible joint to
transmission or
front propeller M12 Nm 60 60 60
shaft
Driveshaft
Number Designation Model 202 Model 208 Model 210
BA41.10-P- Self-locking nut of M10 Nm 40 40 40
1001-01A flexible joint to
transmission or
front propeller M12 Nm 60 60 60
shaft
Fig. 7: Identifying Grab Handle (168 589 00 62 00)
Fig. 8: Identifying Pliers (210 589 00 37 00)

Number Designation
WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis 6511 1801 00
system, Compact Passenger Car
Workshop equipment
WE58.40-Z-1018-11A Transmission platform
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Repair materials
Number Designation Order number
BR00.45-Z-1009-06A Multi-purpose paste A 000 989 80 51 10
Disconnecting and connecting plug connector - AR27.10-P-0500-01A
HOUSING
Number Designation Transmission 722.6 except
722.660/661/662/663/666/674
BA27.40-P-1014- Bolt, heat shield to Nm 6
01A transmission
housing
1. Unscrew bolt (62a) .

2. Undo bolt (62b)
3. Remove heat shield (62)
Heat shield (62) not installed on model 463.
Fig. 9: Identifying Heat Shield And Bolts
4. Turn bayonet fitting of pilot bushing (21) 90° to the left and detach electrical connector (26).
Replace O-ring of electrical connector (26).
5. Install in the reverse order.
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Fig. 10: Identifying Pilot Bushing And Electrical Connector
FASTEN TRANSMISSION TO ASSEMBLY STAND SUPPORT PLATE FOR MOUNTING

TRANSMISSION - AR27.10-P-0600-01B
Only for transmission 722.626
Fig. 11: Identifying Assembly Stand (140 589 34 63 00)
Fig. 12: Identifying Support Plate (140 589 34 63 00)
1. Bolt support plate (071) to assembly stand (070).

2. Insert transmission into support plate (071) and secure with three bolts (arrows).
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Fig. 13: Identifying Support Plate & Assembly Stand
Fig. 14: Identifying Transmission & Support Plate
REMOVE/INSTALL ELECTROHYDRAULIC CONTROLLER UNIT (TRANSMISSION

INSTALLED) - AR27.19-P-0200A
TRANSMISSION 722.6 in MODEL 129, 140, 163, 170, 202, 208, 210, 211, 215, 220, 230 (except,
220.874/876)
TRANSMISSION 722.6 in MODEL 461, 463 (except 461.331, 463.270 /271)
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Fig. 15: Identifying Electrohydraulic Controller Unit Components
Modification notes
10.5.05 Carry out transmission Step 15.1
adaptation inserted
Remove/install
Before starting work,
the area around the
transmission separation
points must be
thoroughly cleaned.
Even the smallest dirt
particles, introduced
into the hydraulic
components, can lead
to malfunctions and a
total failure of the
transmission
1 Switch ignition off, Vehicles with Keyless Go
remove ignition key code 889: Press the Keyless-Go
(transmitter key). start and stop button repeatedly
until the ignition is switched off.
Remove the Keyless Go
transmitter card or transmitter
key from the vehicle and store
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beyond the reach of the

transmitter (min. 2 m).
2.1 Raise vehicle with Models 461,463 AR00.60-P-1000G
lifting platform
2.2 Remove rear part Model 140 with gasoline engine:
section of engine Detach rear section of the lower
compartment paneling engine compartment paneling on
the vehicle underbody and
remove downwards.
Model 170 AR61.20-P-1105A
Model 163.172/174/175 AR61.20-P-1105GH
Model 211 with gasoline engine AR61.20-P-1105T
Model 215, 220 with gasoline AR61.20-P-1105M
engine
Model 129, 202, 208, 210 with AR61.20-P-1105AB
gasoline engine
Model 230 with gasoline engine AR61.20-P-1105R
2.3 Remove rear part of Model 140, 163 with diesel
bottom sections of engine: Detach rear section of
soundproofing noise bottom section of
soundproofing on vehicle
underbody and remove
downwards.
Model 202 with diesel engine AR94.30-P-5300A
Model 210 with diesel engine AR94.30-P-5300AB
Model 211 with diesel engine AR94.30-P-5300T
Model 220 with diesel engine AR94.30-P-5300M
3 Detach front retaining Model 230
bracket of rear engine
compartment paneling
4.1 Disconnect plug Model 163, 463
connector (26)
4.2 Detach heat shield (62) Except model 163, 463 AR27.10-P-0500-01A
and unplug connector *BA27.40-P-1014-
(26) 01A
5 Loosen pilot bushing AR27.19-P-0230A
(21), remove from
transmission housing
(2) and replace if
necessary
*BA27.19-P-1003-
01A
Pilot bushing modified BT27.19-P-0004-01A
6 Drain transmission oil; Installation: Replace sealing
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to do this, unscrew oil ring.

drain screw (4) *BA27.10-P-1001-
If the transmission oil is burnt 03A
or contains particles, the oil
cooling lines and oil cooler must
be flushed:
Except model 461, 463 AR27.55-P-0001A
Models 461,463 AR27.55-P-0001GA
7 Remove transmission Installation: Install new
oil pan (3) gasket
*BA27.10-P-1002-
03A
8 Remove magnet (69) Vehicles as of approx. 04/2001
from transmission oil
pan (3) Clean magnet (69).
Magnet (69) in Passenger cars only BT27.40-P-0003-01A
transmission oil pan
(3), added for the first
time
9 Remove oil filter (5)
10 Remove bolt (19a) and Pay attention to the positions
detach electric of the punched windows in the
controller unit (Y3/6) pulse rings through the rpm
sensor n3 hole (a) and the rpm
sensor n2 hole(b).
If plastic part of selector valve
does not engage in driver of
detent plate: ?
Insert selector valve in driver of AR27.19-P-0200-01A
detent plate.
Disassemble/assemble electric AR27.19-P-0220A
controller unit (Y3/6).
*BA27.19-P-1001-
01A
order
12 Add oil to transmission AR27.00-P-0101A
and check oil level
13 Read out fault memory
with STAR
DIAGNOSIS and erase
if necessary
14 Perform transmission After replacing or repairing
adaptation transmission, perform
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transmission adaptation.
Risk of accident Secure vehicle to prevent it from AS00.00-Z-0005-01A
caused by vehicle moving by itself.
starting off by itself Wear closed and snug-fitting
when engine is work clothes.
running. Risk of injury Do not touch hot or rotating
caused by contusions parts.
and burns during
starting procedure or
when working near the
engine as it is running
15 Perform engine test run
and check transmission
for leaks and that it is
Oil pan, automatic transmission

722.6 except 722.628 722.649
722.628/ 648/649
BA27.10-P- Oil drain screw Nm 20 20 22
1001-03A to oil pan
BA27.10-P- Bolt, oil pan to Nm 8 8 8
1002-03A transmission
housing Angle° - - -
Electrohydraulic controller unit

BA27.19-P-1001- Bolt, electrohydraulic Stage 1 Nm 8
01A controller unit to
transmission housing Stage 2 Angle° -
BA27.19-P-1003- Bolt, pilot bushing to electrohydraulic Nm 3
01A controller unit
Housing
Number Designation Transmission 722.6 except Transmission
722.660/661/662 /663/666/674 722.660/661/66
2/663/666/674
BA27.40-P- Bolt, heat Nm 6 6
1014-01A shield to
transmission
housing
Insert selector valve into driver of detent plate - AR27.19-P-0200-01A
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1. When inserting electrohydraulic control unit into transmission housing, plastic part of selector valve (10)
must engage in driver of detent plate (11).
Fig. 16: Identifying Plastic Part Of Selector Valve, Driver Of Detent Plate
DISASSEMBLE AND ASSEMBLE ELECTROHYDRAULIC CONTROL UNIT - AR27.19-P-0220A
Transmission 722.6 in MODELS 129, 140, 163, 170, 199, 202, 208, 210, 211, 215, 220, 230, 240
Transmission 722.6 in MODELS 461.302 /332 /342 /345,

463.206 /209 /232 /233 /240 /241 /243 /244 /245 /246 /247 /248 /249 /250 /254 /270 /271 /308 /309 /322 /323 /33
Shown on the electrohydraulic control unit in model 163
Fig. 17: Identifying Shift Plate, Electrical Control Unit Disassemble And Assemble - Shown On The
Electrohydraulic Control Unit In Model 163
Modification notes
24.9.97 Remove caps Step 1 new
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24.9.97 Caps for solenoid valves, Step 1 BT27.19-P-0003-01A

new
Disassemble/assemble
1 Take off caps of solenoid valves Only on
transmission 722.6 as
of 1.8.97
Caps for solenoid valve, new Transmission 722.6 BT27.19-P-0003-01A
2 Unscrew bolts (17a, 17b) and Installation: Note
remove leaf springs (17) the different lengths of
the bolts (17a, 17b).
*BA27.19-P-1002-
01A
3 Use pliers to pull modulating Installation:
pressure control solenoid valve Check the O-rings on
(Y3/6y1) and shift pressure the modulating
control solenoid valve (Y3/6y2) pressure control
out of shift plate (16) solenoid valve
(Y3/6y1) and on the
shift pressure control
solenoid valve
(Y3/6y2); fit a new
valve if necessary.
Pliers Fig. 18
4 Use pliers to pull 1-2 and 4-5 shift Installation:
solenoid valve (Y3/6y3), 3-4 shift Check the O-rings on
solenoid valve (Y3/6y4) and 2-3 the 1-2 and 4-5 shift
shift solenoid valve (Y3/6y5) out solenoid valve
of shift plate (16) (Y3/6y3), 3-4 shift
solenoid valve
(Y3/6y4) and 2-3 shift
solenoid valve
(Y3/6y5); fit a new
valve if necessary.
Pliers Fig. 18
5.1 Remove electric control unit Transmission 722.6 up
(Y3/6) from shift plate (16) to end no. 0026194
Installation: Make
sure that the two
centering pins of the
electric control unit
(Y3/6) engage in the
shift plate (16).
5.2 Bend retaining lug on stiffening Transmission 722.6 as
rib on oil-temperature sensor to of end no. 0026195
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one side and remove electric

control unit (Y3/6) from shift
plate (16)
Retaining lug added to 722.6 BT27.19-P-0001-01A
electrohydraulic control unit
6 Disassemble shift plate (16) Only when the shift AR27.35-P-0350A
plate (16) is dirty or
metal shavings are
present in the
transmission oil.
7 Assemble in the reverse order
Electrohydraulic control unit

BA27.19-P-1002-01A Bolt, solenoid valve to Nm 8
shift plate
REPLACE PILOT BUSHING IN THE ELECTROHYDRAULIC CONTROL UNIT - AR27.19-P-0230A
TRANSMISSIONS 722.6
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Fig. 19: Identifying Electrohydraulic Control Unit Components
Remove/Install
In order to prevent
damage to the electric
control unit, the
transmission oil
temperature must be < 50
°C when removing and
installing the pilot
bushing (21).
1.1 Switch off ignition, Vehicles without Keyless
remove ignition key from Go
the EIS [EZS] control unit
1.2 Remove Keyless Go Vehicles with Keyless Go
transmitter (ignition key/ Code 889
card) from the vehicle and Switch off engine.
store outside the
transmitter range
2.1 Detach rear section of Vehicles with gasoline
engine compartment engine except model 461
paneling and 463
Model 129,202,208,210 AR61.20-P-1105AB
Model 140
Model Series 163 AR61.20-P-1105GH
Model 170, 202.0 AR61.20-P-1105A
Model 171 AR61.20-P-1105V
Model 199 AR61.20-P-1105SLR
Model 203, 209 AR61.20-P-1105P
Model 211 AR61.20-P-1105T
Model 215, 220 AR61.20-P-1105M
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Model 230 AR61.20-P-1105R

Model 240 AR61.20-P-1105H
2.2 Detach rear section of Vehicles with diesel
bottom sections of engines except model 461
soundproofing and 463
Model 202.1 AR94.30-P-5300A
Model 203, 209 AR94.30-P-5300P
Model 211 AR94.30-P-5300T
Model 220 AR94.30-P-5300M
3.1 Disconnect plug Model 163, 463
connector (26)
3.2 Detach heat shield (62) Except model 163, 463 AR27.10-P-0500-01A
and unplug connector (26) *BA27.40-P-1014-01A
4 Unscrew bolt (22) and When pulling out the
remove pilot bushing (21) pilot bushing (21), pay
from the electrohydraulic attention to transmission
control unit (19) oil which runs out.
If there is a green spot
on the pilot bushing (21),
only the sealing rings need
to be replaced and not the
complete pilot bushing.
*BA27.19-P-1003-01A
5 Install in the reverse order
6 Pour ATF into automatic Except model 171, 199, AR27.00-P-0101A
transmission and inspect 203, 209, 219,
ATF level 463.270/271
Model 171 AR27.00-P-0101V
Model 203, 209 AR27.00-P-0101P
Model 219 AR27.00-P-0101TZ
Model 463.270/271 AR27.00-P-0101GX
ELECTROHYDRAULIC CONTROL UNIT

BA27.19-P-1003-01A Bolt, pilot bushing to Nm 3
electrohydraulic control
unit
HOUSING
Transmission
Transmission 722.6 except 722.660/661/66
Microsoft
Number Designation 722.660/661/662 /663/666/674 2/663/666/674

BA27.40-P- Bolt, heat Nm 6 6
1014-01A shield to
transmission
housing
REMOVE/INSTALL TORQUE CONVERTER - AR27.20-P-0500-01B
Test values for torque converter

Transmission
722.620/622/ Transmission
Number Designation 625/627 722.621
BE27.20-P- Installed Distance from mm 26 (-2) 19 (-2)
1001-01B height of transmission
torque housing
converter
Torque converter test values

722.600/601/602/603/ 722.606/607/609/610/
604/605/608/611/614/ 617/618/623/624/628/
616/619/626/629/634/ 630/631/632/633/636/
637/640/642/660/661/ 643/645/662/663/664/
682/683/695/699 665/666/667/668/669/
672/676/680/690/696/
698
BE27.20-P- Installed Distance from mm 7 (-2) 19.5 (-2)
torque housing
converter
Torque converter test values

722.635/639/ 644 722.638 722.649
BE27.20-P- Installed Distance from mm 21 (-2) 26 (-2) 20 (-2)
torque housing
converter
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Fig. 20: Identifying Grab Handle (168 589 00 62 00)
Repair materials
BR00.45-Z-1009-06A Multi-purpose paste A 000 989 80 51 10
Remove torque converter
1. Position transmission vertically.

2. Fit grab handles (065) to torque converter.
3. Remove torque converter from transmission housing.
4.1 If there are metal shavings in the transmission oil pan: Drain transmission oil from torque converter
through a clean cloth.
If there are metal chips in the cloth, replace torque converter. In case of doubt flush out the torque
converter with transmission oil.
Remaining metal chips can cause transmission damage!
5.1 If transmission oil is burnt or interspersed with abrasive particles: Flush oil cooler lines and oil cooler.
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Fig. 22: Identifying Grab Handles On Torque Converter
Install torque converter
6 Grease the crankshaft journals with multi-purpose paste and insert torque converter into transmission
housing.
Do not use force, otherwise the axial stop of the torque converter will be destroyed.
Move torque converter back and forth so that the teeth on the torque converter and the transmission
primary pump engage in one another.
Fig. 23: Identifying Torque Converter And Transmission Housing
Measure installed height of torque converter in transmission housing
7 Measure dimension "A" between transmission housing and torque converter mounting using a depth
gauge.
Torque converter and primary pump will be damaged if torque converter is seated incorrectly in
transmission housing.
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Fig. 24: Identifying Measure Dimension Between Transmission Housing And Torque Converter
Mounting
DISMANTLE AND ASSEMBLE SHIFT PLATE - AR27.35-P-0350A
TRANSMISSION 722.6
TRANSMISSION 722.610 in MODELS 463.209 /232 /233 /244 /245 /250
TRANSMISSION 722.611 in MODEL 463.308 /330 /331
TRANSMISSION 722.630 in MODEL 463.206 /240 /241 /243 /246 /247 /248 /249 /254
TRANSMISSION 722.637 in MODEL 461.302 /331 /332 /342 /345, 463.322 /323
TRANSMISSION 722.638 in MODEL 463.309 /332 /333 722.645 in MODEL 463.270 /271
Location of regulating valve
Fig. 25: Identifying Shift Plate Disassemble/Assemble Components (1 Of 5)

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Microsoft
1 Remove leaf spring (82)
2 Remove valve body (72) from Assembly: Insert
valve housing (74) locating pin (59) into valve
housing (74) (arrow).
*BA27.35-P-1001-
03A
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Assembly: Observe for

transmission 722.6 as of
end number 0538312:
Strainer for modulating pressure Transmission 722.6 BT27.35-P-0004-
and shift pressure control 01A
solenoid valve, new
end number 0485895:
Strainer in inlet to converter Transmission 722.6 BT27.35-P-0005-
lock-up control solenoid valve, 01A
new
3 Remove gasket (73) Located in the valve
housing (74) are four
plastic valve balls (75) and
eight steel valve balls (76).
4 Remove side cover from valve All the valves are only
housing (74) and valve body to be checked for easy
(72) movement and swarf in
case of requirement
*BA27.35-P-1002-
03A
Assembly:
The sleeves and pistons of
the components
 regulating valve, "2-

3" overlap with
sleeve and piston
(72.2),
 "3-4" overlap
regulating valve
with sleeve and
piston (72.8)
 and "1-2" and "4-5"
overlap regulating
valve with sleeve
and piston (74.18)
must not be
interchanged as
otherwise
malfunctions will
occur.
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The shift valve "multi-

disk brake B2" (74.27) can
only be removed and
installed if the valve body
(72) has been removed.
end number 0027083:
Installation of a pressure feed BT27.35-P-0002-
valve 01A
5 Wash all parts and blow them Ensure that parts are
clean using compressed air not blown away. Only rags
made of leather should be
used to clean parts.
6 Assemble in reverse order
Tightening torques of valve housing

BA27.35-P-1001- Bolt, valve body to M6x30 Nm 8
03A valve housing
BA27.35-P-1002- Bolt, side cover to M4x12 Nm 4
03A valve body and
valve housing
ASSEMBLE/INSTALL TRANSMISSION HOUSING COMPONENTS - AR27.50-P-0600
Screw on and secure twelve-point collared nut and secure - AR27.50-P-0600-04B
Gear set
Transmission 722.6
Number Designation 722.9
BA27.50-P-1001-01A Collared nut, output NM 200
flange to output shaft
Fig. 30: Identifying Wrench Socket (126 589 02 09 00)
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1. Block transmission gear assembly by engaging park pawl.

2. Push output flange (48) onto the output shaft.
Transmission 722.611: On this model the output flange is not designed as a three-arm flange, the
attachment to the output shaft with the aid of a twelve-point collar nut corresponds to that on the three-
arm flange.
3. Fasten twelve-point collar nut (47) using the socket wrench bit 126 589 02 09 00.
Replace twelve-point collar nut (47).
4. Secure twelve-point collar nut (47) by hammering the collar into the recess in the output shaft. (Arrow)
Fig. 31: Identifying Twelve-Point Collar Nut, Output Flange
Install grooved ball bearing in rear transmission housing - AR27.50-P-0600-05A
1. Press grooved ball bearing (67) into transmission housing using a suitable drift.
Closed side of plastic cage must face towards park pawl gear.
2. Fit circlip (68) in groove.

3. Use feeler gage to determine play between grooved ball bearing (67) and circlip (68).
No play should exist between circlip (68) and grooved ball bearing (67). If circlip cannot be fitted, a
thinner one must be used. If play exists between circlip and grooved ball bearing, a thicker circlip must be
used.
Circlips (68) are available in thicknesses 2.0, 2.1 and 2.2 mm.
Microsoft
Fig. 32: Identifying Grooved Ball Bearing In Rear Transmission Housing
Measure end play between park pawl gear and grooved ball bearing - AR27.50-P-0600-06A
Test values for gear set

Number Designation Transmission 722.6 Transmission 722.9
BE27.50-P-1004- End play between mm 0.3...0.5 0.20...0.40
01A park pawl gear and
grooved ball
bearing
Fig. 33: Identifying Parallel Support (126 589 04 31 00)
Determine measurement "a"
1. Fit parallel support (029) on transmission housing. Using the depth gauge measure from the parallel
support (029) to the park pawl gear (15).
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Fig. 34: Measuring Parallel Support To Park Pawl Gear
Determine measurement "b"
2. Using the depth gauge measure from the parallel support (029) to the contact surface of the grooved ball
bearing (67) in the transmission housing.
Fig. 35: Measuring Parallel Support To Contact Surface Of Grooved Ball Bearing In Transmission
Housing
3. Adjust the axial play "E" by means of shim as per the calculation example.
Example calculation:
Dimension "a" 49.9 mm
Dimension "b" 49.0 mm
Difference 0.9 mm
Axial play "E" - 0.4 mm
Shim 0.5 mm
4. Install the corresponding shim.

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Shims are available in thicknesses of 0.2 to 0.5 mm. The graduation is 0.1 mm.
DETACH/ATTACH TRANSMISSION HOUSING ON TORQUE CONVERTER HOUSING. - AR27.50-

P-0601A
TRANSMISSION 722.6
Fig. 36: Identifying Transmission Housing On Torque Converter Housing Detach/Attach Components
Modification notes
27.7.01 Magnet in oil pan, newly Step 4 and 26 added BT27.40-P-0003-01A
included
Disassemble
1 Fasten transmission on AR27.10-P-0600-01B
assembly stand
Assembly stand Fig. 37
Support plate Fig. 11
Support plate for WF58.50-P-2750-04A
transmission mount
2 Loosen guide bush (21)
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and remove from

3 Detach oil pan (3)
4 Remove magnet (69) from Vehicles as of 04/2001. BT27.40-P-0003-01A
oil pan Magnet in oil pan, newly
included
5 Remove oil filter (5)
6 Unscrew Torx socket According to AR27.19-P-0220A
bolts (19a) and remove condition:
electrohydraulic control Disassemble and assemble
unit (19) electrohydraulic control
unit
7 Detach output flange (48) Socket wrench bit Fig. 30
Model 463: The output
flange is not designed as a
three-arm flange but as a
cylindrical flange
8 Press out radial seal ring
(20)
9 Remove shim (67a) As of transmission no.
1658778.
10 Remove circlip (68)
11 Remove deep-groove ball AR27.50-P-0601-01A
bearing (67) from Puller Fig. 44
transmission housing Fig. 45
Tensioning clamp
12 Remove shim (18)
13 Unscrew Torx socket Torx insert for Torx *WH58.30-Z-1039-06A
bolts (1 a, 2a) from bolts
converter housing and
14 Remove transmission Continued operations
housing (2) from according to findings: ?
converter housing (1) Remove/install multi-disc AR27.50-P-0621A
clutch K1, K2 and K3 AR27.50-P-0781A
Remove/install multiple-
disc brake B2, multiple-
disk pack B3 and park
pawl gear
Assemble
15 Using grease, install both
Teflon rings (12a) in the
groove so that the joint
stays together
16 Mount transmission Align discs of
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housing (2) on converter multiple-disc brakes B2

housing (1) and B3.
17 Screw in Torx socket *BA27.40-P-1002-01A
bolts (1a, 2a)
18 Measure end play between Only necessary when AR27.50-P-0600-06A
park pawl gear and installing new parts, e.g.
grooved ball bearing gear set, output shaft etc.
Steel straightedge Fig. 33
*BE27.50-P-1004-01A
19 Install shim (18)
20 Install grooved ball AR27.50-P-0600-05A
bearing in rear
21 Insert shim (67a) As of transmission no.
1658778.
Additional shim between Transmission 722.6 BT27.10-P-0005-01A
grooved ball bearing and
output flange
22 Drive radial seal ring (20) Drift Fig. 38
into transmission housing
23 Install output flange (48) AR27.50-P-0600-04B
Socket wrench bit Fig. 30
*BA27.50-P-1001-01A
24 Install and tighten BA27.19-P-1001-01A
electrohydraulic control
unit (19)
25 Install oil filter (5)
26 Insert magnet (69) in oil Vehicles as of 04/2001. BT27.40-P-0003-01A
pan Clean abrasion
particles from magnet.
Magnet in oil pan, newly
included
27 Mount oil pan (3) *BA27.10-P-1002-03A
28 Insert guide bush (21) in
transmission housing and
tighten

BE27.50-P-1004-01A End play between park mm 0,3-0,5
pawl gear and grooved
ball bearing
Housing
Microsoft

except 722.660/661/66
2/663/666/674
BA27.40-P-1002-01A Bolt, transmission Nm 20
housing to torque
converter housing
Automatic transmission oil pan

Transmission 722.6
Number Designation except 722.628/ 648/649
BA27.10-P-1002-03A Bolt, oil pan to Nm 8
transmission housing Angle -
Gear assembly
Transmission 722.6
Number Designation 722.9
BA27.50-P-1001-01A Collar nut, output flange Nm 200
to output shaft
Electrohydraulic control unit

BA27.19-P-1001- Bolt, electrohydraulic 1st stage Nm 8
01A control unit to
transmission housing 2nd stage Angle -
Fig. 37: Identifying Assembly Stand (116 589 06 59 00)
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Fig. 38: Identifying Drift (140 589 12 15 00)
Fig. 39: Identifying Socket Wrench Bit (126 589 02 09 00)
Fig. 40: Identifying Puller (001 589 50 33 00)
Fig. 41: Identifying Support Plate (140 589 34 63 00)
Fig. 42: Identifying Collet Chuck (140 589 06 34 00)
Microsoft
Fig. 43: Identifying Parallel Support (126 589 04 31 00)

Number Designation
WH58.30-Z-1039-06A Torx insert for Torx bolts
Remove grooved ball bearing in rear of transmission housing - AR27.50-P-0601-01A
Fig. 44: Identifying Puller (001 589 50 33 00)
Fig. 45: Identifying Clamping Pliers (140 589 06 34 00)
1. Screw in clamping pliers in puller and tighten.

2. Position puller above bearing inner race.
3. Turning top part of puller counterclockwise (arrow) tightens clamping pliers (figure A).
4. Use puller to pull grooved ball bearing out of transmission housing (figure B).
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Fig. 46: Turning Top Part Of Puller Counterclockwise
Fig. 47: Pulling Grooved Ball Bearing Out Of Transmission Housing
REMOVING AND INSTALLING MULTIPLE-DISC CLUTCHES K1, K2 AND K3 - AR27.50-P-0621A
TRANSMISSION 722.6
Microsoft
Fig. 48: Identifying Multiple-Disc Clutches K1, K2 And K3 Removing And Installing Components
Dismantling
1 Remove transmission AR27.50-P-0601A
housing from converter
housing
2 Remove output shaft with According to
center and rear gear set findings ?
and clutch K3 (12) Dismantle and assemble AR27.50-P-0810A
output shaft with center
and rear gear set and K3
Dismantle and assemble AR27.51-P-0830A
clutch K3
3 Remove thrust needle
bearing (13) and thrust
washer (13a)
4 Remove drive shaft with According to
clutch K2 and front gear findings ?
set (58)
drive shaft with clutch K2
and front gear set
5 Remove clutch K1 (83) According to
findings ?
Remove, install multiple- AR27.50-P-0721A
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disc brake B1 and oil

pump
Dismantle and assemble AR27.51-P-0800B
clutch K1
Assembly
6 Using grease, insert *BR00.45-Z-1007-06A
Teflon rings in the
multiple-disc brake B1 in
the groove so that the
joint remains together
7 Mount clutch K1 (83)
8 Using grease, insert
Teflon rings (58a) in the
groove so that the joint
remains together
9 Install drive shaft with
clutch K2 and front gear
set (58)
10 Install front washer (13a)
and thrust needle bearing
(13)
11 Install output shaft with
center and rear gear set
and clutch K3 (12)
12 Install transmission AR27.50-P-0601A
housing on converter
housing
Repair materials
BR00.45-Z-1007-06A Grease A 001 989 37 51
DISMANTLING AND ASSEMBLING OIL PUMP - AR27.50-P-0720-01A
1. Remove pump gears (22 and 23) from pump housing

2. Check radial seal ring (24), replace if necessary
3. Replace O-ring (25)
4. Lubricate pump gears and place in the pump housing. Insert pump gear (22) so that the chamfer (arrow)
points towards the pump housing.
Use ATF oil
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Fig. 49: Identifying Pump Gears From Pump Housing
Fig. 50: Identifying Radial Seal Ring And O-Ring
REMOVE/INSTALL MULTI-DISK BRAKE B1 AND OIL PUMP - AR27.50-P-0721A
TRANSMISSION 722.6
Microsoft
Fig. 51: Identifying Multi-Disk Brake B1 And Oil Pump Remove/Install Components (1 Of 2)
Fig. 52: Identifying Multi-Disk Brake B1 And Oil Pump Remove/Install Components (2 Of 2)
Modification notes
2.8.00 Figure modified from 8 Value modified in *BA27.40-P-1004-01A
Nm to 10 Nm BA27.40-P-1004-01A for
transmission 722.6
Dismantle
1 Remove multi-disk clutch AR27.50-P-0621A
K1, K2 and K3
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2 Unscrew Torx socket Removal: Screw two

bolts (7a) and remove oil opposed bolts into the oil
pump (7) pump housing and press
the oil pump out of the
converter housing by
applying light blows with
a plastic hammer.
According to
findings ?
Dismantle and assemble AR27.50-P-0720-01A
oil pump
3 Unscrew Torx socket Removal: Screw two
bolts (6a) and remove opposed bolts into the
multi-disk brake B1 (6) multi-disk brake B1 and
from converter housing separate from the
converter housing by
applying light blows with
a plastic hammer.
According to
findings ?
multi-disk brake B1
4 Detach intermediate Use a suitable tool for
panel (8) from converter loosening
housing (1) Additional work ?
Remove/install multi-disk AR27.50-P-0781A
brake B2, multi-disk pack
B3 and park pawl gear
Assembling
5 Place intermediate panel The intermediate
(8) on converter housing panel can generally be
(1) and align used several times. The
panel must not be coated
with sealant
6 Securely tighten multi- Installed position of
disk brake B1 (6) on multi-disk brake B1 in
converter housing (1) relation to converter
housing is specified by a
plain dowel pin in the
multi-disk brake B1
(arrow).
*BA27.40-P-1004-01A
7 Install oil pump (7) and *BA27.40-P-1003-01A
securely tighten
8 Install multi-disk clutch AR27.50-P-0621A
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K1, K2 and K3
Housing
Transmission 722.6
except 722.660/661/66
Number Designation 2/663/666/674
BA27.40-P-1003-01A Bolt, oil pump with Nm 20
multi-disk brake B1 to
torque converter housing
BA27.40-P-1004-01A Bolt, multi-disk brake B1 Nm 10
to converter housing
INSERTING AND MEASURING MULTIPLE-DISC PACK B3 - AR27.50-P-0780-11A
Adjustment values of multi-disk clutch

BE27.50-P- Play in multiple-disc brake B3 mm 1,0...1,4
1003-02B Number of 3 mm -
multiple-discs 4 mm -
Fig. 53: Identifying Transmission Housing (External Plate Carrier/B3)
Place new friction plates in ATF fluid 1 hour before installation.
1. Assemble lamella for the multi-disk brake B3 in the sequence shown in the picture and insert
individually.
2. Using a feeler gage, measure the clearance "L" at three points between the snap ring (133a) and externally
toothed plate (133c).
For the measuring procedure the snap ring (133a) must abut the upper contact surface of the groove in
the external plate carrier.
3. with snap ring (133a), adjust if necessary.
Snap rings are available in thicknesses of 3.2, 3.5, 3.8, 4.1, 4.4 and 4.7 mm
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Fig. 54: Identifying Externally Toothed Plate, Snap Ring
REMOVING AND INSTALLING MULTI-DISK BRAKE B2, DISK PACK B3 AND PARK PAWL
GEAR - AR27.50-P-0781A
TRANSMISSION 722.6
Fig. 55: Identifying Multi-Disk Brake B2, Disk Pack B3 And Park Pawl Gear Remove/Install
Components
Disassembling
1 Detach transmission AR27.50-P-0601A
housing from torque Bracket for transmission WF58.50-P-2750-03A
converter housing housing
This bracket may only
be used if the torque
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converter housing with

gear sets has been
detached from the
transmission housing.
2 Remove disk pack B3 To facilitate removal
(133) and disk spring of the snap ring (133a),
(133b) by removing snap compress the disk pack
ring (133a) in B3 (133).
transmission housing Check disks for scorch
marks and wear.
3 Unscrew torx socket bolts
(11)
4 Remove multi-disk brake The externally toothed AR27.50-P-0880A
B2 (14) from disk carrier for multi-disk
transmission housing brake B2 is also the
piston for multi-disk
brake B3
According to findings: ?
Disassembling and
assembling multi-disk
brake B2.
5 Remove park pawl gear
(15)
Assembling
6 Insert park pawl gear (15)
7 Install multi-disk brake
B2 (14) in transmission
housing (2)
8 Screw in torx socket bolts *BA27.40-P-1005-01A
(11)
9 Insert and measure disk Pay attention to AR27.50-P-0780-11A
spring (133b) and disk sequence of disks.
pack B3 (133)
Survey of multiple-disk Transmission 722.6 GF27.51-P-5200A
components, production
details
10 Fit snap ring (133a)
11 Attach transmission AR27.50-P-0601A
housing to torque
converter housing
Housing
except 722.660/661/66
2/663/666/674
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BA27.40-P-1005- Bolt, multi-disk 1st stage Nm 16

01A brake B2 to
transmission 2nd stage Angle -
housing
DISMANTLING AND ASSEMBLING OUTPUT SHAFT WITH CENTER AND REAR GEAR SET -
AR27.50-P-0810A
TRANSMISSION 722.6
Fig. 56: Identifying Output Shaft With Center And Rear Gear Set Dismantle And Assemble Components
Disassembling
housing from torque
converter housing
2 Remove multi-plate AR27.50-P-0621A
clutch K1, K2 and K3
3 Remove upper two
visible Teflon rings (42b)
from output shaft
4 Remove circlip (42f),
shim (42e), thrust needle
bearing (42d) and thrust
washer (42c) from output
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shaft
5 Remove clutch K3 (44) According to
condition: ?
Disassemble clutch K3 AR27.51-P-0830A
and assemble
6 Remove rear tubular shaft According to
(45) from output shaft condition: ?
rear tubular shaft
N Remove rear gear set (43)
with integrated tubular
shaft of center gear set
from output shaft
Conversion from 18° to Transmission 722.6 BT27.50-P-0012-01A
23° teeth in front and rear
planetary gear set
8 Remove thrust washer
(43a)
9 Remove multi-disk brake AR27.50-P-0721A
B1 and oil pump, install
Assembling
10 Mount thrust washer
(43a) with the collar
pointing towards the
planet carrier
11 Mount rear gear set (43)
with integrated tubular
shaft of the center gear
set on output shaft
12 Using grease, install *BR00.45-Z-1007-06A
lower three Teflon rings
(42b) in the groove so
that the joint stays
together
13 Put rear tubular shaft (45) Inspect O-rings on
on output shaft hollow shaft, replace if
necessary.
14 Install clutch K3 (44)
15 Mount circlip, shim,
thrust needle bearing and
thrust washer (42c - 42f)
16 Using grease, insert the
upper two Teflon rings
(42b) in the groove so
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that the joint remains

together
17 Inspect axial play AR27.50-P-0810-01A
between shim (42e) and *BE27.50-P-1005-01A
circlip (42f)
18 Install multiple-disc AR27.50-P-0621A
clutch K1, K2 and K3
Multi-disk clutch
BE27.50-P-1005-01A Axial play between shim mm 0.15- 0.6
and circlip
Repair materials
BR00.45-Z-1007-06A Grease A 001 989 37 51
Checking and adjusting end play between shim and circlip - AR27.50-P-0810-01A

Number Designation Transmission 722.6 Transmission 722.9
BE27.50-P-1005- Axial play mm 0.15...0.6 0.15...0.60
01A between shim and
circlip
1. Using a feeler gage, check axial play "S" between shim (42e) and circlip (42f).
Push multi-disk clutch K3 (44) hard by hand in direction of arrow.
2. Remove shim (42e) and measure thickness.

3. Adjust play with shim (42e).
Shims (42e) are available in thicknesses 3.1 to 3.7 mm. They are available in graduations of 0.3 mm.
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Fig. 57: Identifying Multi-Disk Clutch K3
DISASSEMBLING AND ASSEMBLING REAR HOLLOW SHAFT WITH REAR FREEWHEEL -

AR27.50-P-0850A
TRANSMISSION 722.6
Fig. 58: Identifying Rear Hollow Shaft With Rear Freewheel Disassemble And Assemble Components
1 Detach transmission housing AR27.50-P-0601A
from torque converter housing
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2 Remove multi-disk clutch K1, AR27.50-P-0621A

K2 and K3
3 Remove circlip (45h), shim Installation: Check
(45g), axle needle roller bearing that circlip is correctly
(45f) from hollow shaft (45a). seated.
Check O-rings (45b),
replace if necessary.
If using BT27.50-P-
0011-01A , axial needle
roller bearing and shim
are no longer required.
4 Remove rear sun gear (45e) with Installation: Install
internally toothed disk carrier/ hollow shaft (45a) on
K3 and rear freewheel (45d). freewheel and press in
while turning
counterclockwise
Friction bearing in sun gear of Transmission 722.6 BT27.50-P-0011-01A
rear planetary gearset converted
to anti-friction bearing
5 Remove snap ring (45c) for
freewheel
6 Press freewheel out of sun gear. Installation: The
thrust plate of the
freewheel (45d) must
face the snap ring (45c).
7 Assemble in reverse order
DISMANTLING AND ASSEMBLING MULTI-DISK BRAKE B1 - AR27.50-P-0870A
TRANSMISSION 722.6
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Fig. 59: Identifying Multi-Disk Brake B1 Dismantle And Assemble Components
Modification notes
25.8.98 New special tool for AR27.50-P-0870-01A
setting clearance
16.9.02 Multi-disks for B1, K1 Transmission 722.6 as of BT27.50-P-0013-01A
and K3 changed 02.09.02, refer to step 10.
Dismantling
1 Remove snap ring (6h)
2 Remove multi-disk pack Check multi-disks for
(6g) and spring washer scorch marks and wear.
(6f) from external plate
carrier
3 Place assembly device Assembly device Fig. 60
(073) on spring washer
(6d) and tension until
the snap ring (6e) is
exposed
4 Remove snap ring (6e)
5 Remove piston (6c)
from the external plate
carrier by carefully
blowing compressed air
into the bore (A).
Microsoft
Assemble
6 Install piston (6c) in Inspect molded gasket,
external plate carrier replace if necessary.
Press in the piston with
the assistance of the spring
washer (6d) and the assembly
device (073).
7 Insert spring washer Insert spring washer with
(6d) the curvature towards the
multi-disk pack.
(073) on spring washer
the groove of the snap
ring is exposed
9 Insert snap ring (6e) The collar of the snap ring
must point towards the multi-
disk pack.
After installing, check snap
ring for correct seat
10 Insert spring washer (6f) Observe outer multi-disk
and multi-disk pack (6g) sequence Inserting and
in the external plate measuring multi-disk pack
carrier and measure B1: ?
TRANSMISSION 722.6 up AR27.50-P-0870-01A
to 01.09.02
Pressing tool Fig. 62
Clearance of multi-disk *BE27.50-P-1001-02B
brake B1
Transmission 722.6 as of AR27.50-P-0870-01AA
02.09.02
Clearance of multi-disk *BE27.50-P-1001-02B
brake B1
Thickness of steel multi- Transmission 722.6 BT27.51-P-0002-01A
disks B1, K1 and K2
changed
External plate carrier B1 Transmission 722.6 BT27.50-P-0008-01A
modified
Multi-disks for B1, K1 Transmission 722.6 as of BT27.50-P-0013-01A
and K3 changed 02.09.02
Survey of multi-disk Transmission 722.6 GF27.51-P-5200A
details
Microsoft
11 Insert snap ring (6h) For additional work, AR27.50-P-0721A

see: ?
Remove/install multi-disk
brake B1 and oil pump

722.6 up to 722.6 as of
01.09.02 with 02.09.02 with
double sided single-sided multi-
multi-disks disks
BE27.50-P- Clearance of Number of 2 mm 2.30...2.70 2.20...2.60
1001-02B multi-disk multi-disks 3 mm 2.70...3.10 2.40...2.80
brake B1 4 mm 3.00...3.40 2.60...3.00
Fig. 60: Identifying Assembly Device (140 589 13 43 00)
Fig. 61: Identifying pressing tool (208 589 00 21 00)
Inserting and measuring multi-disk pack B1 Thickness steel multi-disks B1, K1 and K2 changed - AR27.50-P-0870-01A
Thickness steel multi- BT27.51-P-0002-01A

disks B1, K1 and K2
changed
Modification notes
25.8.98 New special tool for Point 2 and 3 added
setting clearance
Microsoft
30.3.99 New values for clearance

of multi-disk brake

up to 01.09.02 with
double sided multi-
disks
BE27.50-P- Play in multi- Number of 2 mm 2.30...2.70
1001-02B disk brake B1 multi-disks 3 mm 2.70...3.10
4 mm 3.00...3.40
Fig. 62: Identifying Pressing Tool (208 589 00 21 00)
Fig. 63: Identifying External Plate Carrier/B1, Spring Washer And Friction Multi-Disks
Soak new friction multi-disks in automatic transmission fluid for 1 hour before installation.
1. Assemble the disks for multi-disk brake B1 in the sequence shown in the diagram and insert one at a time.
2. Place pressing tool (078) on externally toothed plate (70c).
3. Press together multi-disk pack by pressing together pressing tool as far as stop using a lever press (the
marking ring can then still be seen, refer to small arrow ).
4. Using a feeler gage, measure the clearance "L" at three locations between the snap ring (6h) and the
externally toothed plate (70c).
Microsoft
During the measuring procedure, the snap ring (6h) must touch the upper contact surface of the groove in
5. Adjust clearance if necessary using appropriate snap ring (6h).
Snap rings are available in thicknesses of 2.6, 2.9, 3.2, 3.5, 3.8 and 4.1 mm.
Fig. 64: Identifying Place Pressing Tool On Externally Toothed Plate
Inserting and measuring multiple-disc pack B1 - AR27.50-P-0870-01AA
ADJUSTMENT VALUES OF MULTI-DISK CLUTCH

as of 02.09.02 with
single-sided
multiplediscs
BE27.50-P- Play in Number of 2 mm 2.20...2.60
1001-02B multiple-disc multiplediscs 3 mm 2.40...2.80
brake B1 4 mm 2,60...3,00
Microsoft
Fig. 65: Identifying Thrust Device (208 589 00 21 00)
1. Assemble the new disks for the multi-disk brake B1 in the sequence shown and dismantle individually.
Insert the new disks in ATF oil before installation for 1 h.
Fig. 66: Identifying Clearance Between Snap Ring And End Disk
2. Mount pressure device (078) onto end disk (70c).

3. Compress the disk pack, to do so press the pressure device (078) together using a lever press up to
stop.
The marking ring (smaller arrow) is then still visible.
4. Use a feeler gauge to measure the clearance (L) at three points between the snap ring (6h) and end disk
(70c).
During the measuring procedure, the snap ring (6h) must lie against the upper contact surface of the
groove in the external plate carrier (6b).
5. Use corresponding snap ring (6h) to adjust clearance (L) if necessary.
The snap rings (6h) are available at sizes 2.6 mm, 2.9 mm, 3.2 mm, 3.5 mm, 3.8 mm and 4.1 mm.
Microsoft
Fig. 67: Pressing Pressure Device Using Lever
DISMANTLING AND ASSEMBLING MULTIPLE-DISC BRAKE B2 - AR27.50-P-0880A
TRANSMISSION 722.6
Fig. 68: Identifying Outer Multiple-Disc Carrier B2 Or Piston B3 Dismantle And Assemble Components
(1 Of 2)
Microsoft
Fig. 69: Identifying Outer Multiple-Disc Carrier B2 Or Piston B3 Dismantle And Assemble Components
(2 Of 2)
Fig. 70: Identifying Snap Ring, Assembly Device
Microsoft
Fig. 71: Identifying Piston B2, Piston Guide Ring And Valve
Fig. 72: Identifying Oil Pressure Supply
Modification notes
clearance adjustment
Dismantling
1 Remove snap ring (134a)
2 Take multiple-disc pack The outer multiple-
B2 (134) and disc spring disc carrier for the multi-
(134b) out of outer disc brake B2 is the
multiple-disc carrier B2 piston for the multiple-
disc brake B3 at the same
time.
Check multiple-discs for
burnt spots and wear.
Microsoft
3 Place assembly device Fig. 60

(074) on disc spring (29)
and tension until the
groove for the snap ring is
exposed (figure C)
4 Remove snap ring (31)
5 Remove spring plate (30)
and disc spring (29)
6 Separate piston guide ring
(28) and piston/ multiple-
disc brake B2 (27) from
piston B3 (14a) by
into the bore (D) (figure
E) .
7 Press piston guide ring
(28) out of piston B2 (27)
Peak-to-valley height on Transmission 722.6 BT27.50-P-0009-01A
piston B2 modified
Piston B2 modified Transmission 722.6 BT27.50-P-0010-01A
8 Separate piston guide (32)
from piston B3 (14a) by
into the bore (A) (figure
E) .
Assembling
9 Assemble piston guide AR27.50-P-0880-01A
(32) and piston B3 (14a)
in the correct position
10 Insert piston/multiple-disc Check all sealing
brake B2 (27) in piston B3 rings, replace if
(14a) necessary.
The rounded off edges
on the sealing rings
(14c), (28a) and (28b)
must point outwards The
rounded off edges on the
sealing ring (14d) must
point inwards (figure B)
11 Insert piston guide ring The valve (137) in the
(28) piston guide ring must be
on top (figure D)
12 Insert disc spring (29) and Insert disc spring with
spring plate (30) the curvature towards the
spring plate
Microsoft

(074) on disc spring (29)
and tension until the
groove for the snap ring is
exposed
14 Insert snap ring (31)
15 Insert disc spring (134b) Observe outer AR27.50-P-0880-02A
and multiple-disc pack multiple-disc sequence.
(134) in the outer
multiple-disc carrier B2
and measure
Survey of multiple-disc Transmission 722.6 GF27.51-P-5200A
pack components, as-built
16 Insert snap ring (134a)
Follow up work ?
Remove, install multiple- AR27.50-P-0781A
disc brake B2 and
multiple-disc pack B3
Assembling piston guide and outer multiple-disc carrier of multiple-disc brake - AR27.50-P-0880-01A
Microsoft
Fig. 74: Identifying Piston Guide And Outer Multiple-Disc Carrier Of Multiple-Disc Brake
1. Insert piston guide (32) in transmission housing (2) and tighten securely.
2. Press in outer multiple-disc carrier/B2 (14a) up to the stop in the piston guide (32).
The recess in the external splines or the opening in the outer multiple-disc carrier/B2 (14a) must point
downwards (arrow).
3. Remove assembled component from transmission housing again for further assembly work.
Inserting and measuring multiple-disc pack B2 - AR27.50-P-0880-02A
Modification notes
25.8.98 New special tool for Item 2 and 3 incorporated
clearance adjustment for the first time
30.3.99 New adjustment values
for clearance of multi-
disk brake
Microsoft

BE27.50-P- Play in Number of 4 mm 1,90...2,30
1002-02B multiple-disc multiple-discs 5 mm 2,00...2,40
brake B2 6 m- -
Fig. 76: Identifying Multiple-Disc Pack B2 Components
Place new friction plates in ATF fluid 1 hour before installation.
1. Assemble lamella for the multi-disk brake B2 in the sequence shown in the picture an insert individually.
2. Mount the pressure device (078) on the externally toothed plate (134a).
3. Compress the clutch pack; to do this, compress the pressure device as far as the stop using a lever press
(the marking ring is still visible, see small arrow ).
4. Using a feeler gage, measure the clearance "L" at three points between the snap ring (144a) and externally
toothed plate (134a).
For the measuring procedure the snap ring (144a) must abut the upper contact surface of the groove in
5. with snap ring (144a), adjust if necessary.
Snap rings are available in thicknesses of 2.9, 3.2, 3.5, 3.8 and 4.1 mm
Microsoft
Fig. 77: Identifying Mount Pressure Device On Externally Toothed Plate
DISASSEMBLE/ASSEMBLE CLUTCH K1 - AR27.51-P-0800B
TRANSMISSIONS 722.6
Microsoft
Fig. 78: Identifying Clutch K1 Disassemble/Assemble Components
Fig. 79: Identifying Snap Ring, Assembly Tool
Modification notes
clearance adjustment
16.9.02 Disks for B1, K1 and K3 Transmission 722.6 as BT27.50-P-0013-01A
changed from 02.09.02, see work
step 12.
Microsoft
Disassemble
from outer multiple-disc
carrier
2 Take multiple-disc pack Check multi-disks for
(89) out of outer scorch marks and wear.
multiple-disc carrier
(072) on spring plate (87)
and tension until the snap
ring (88) is exposed
(figure A)
5 Take out disk spring
(86b) and remove piston
(86) by carefully blowing
compressed air into the
bore (A) (figure B) .
6 Remove snap ring (91) According to
and take out front condition.
freewheel (92).
Assemble
7 Install piston (86) in outer Check sealing rings
multiple-disc carrier (83b and 86a), replace if
necessary.
of the sealing rings must
face outwards
8 Insert disc spring (86b). Insert disk spring with
the curvature towards the
piston
9 Insert spring plate (87). Insert spring cup with
curvature towards sun
gear.
(072) on spring plate (87) Check sealing ring
and tension until the (87a), replace if
groove of the snap ring is necessary
exposed
11 Insert snap ring (88) After installing, check
snap ring for correct
seating
12 Insert multiple-disc pack Observe externally-
(89) in the outer multiple- toothed plate sequence.
disc carrier and measure
Microsoft
Insert and measure disk

pack K1: ?
Transmission 722.6 up to AR27.51-P-0800-02AA
01.09.02
Thrust device Fig. 62
Play in multiple-disc *BE27.51-P-1001-01B
clutch K1
Transmission 722.6 as of AR27.51-P-0800-02A
02.09.02
Thrust device Fig. 62
Play in multiple-disc *BE27.51-P-1001-01B
clutch K1
Strength of steel disks Transmission 722.6 BT27.51-P-0002-01A
B1, K1 and K2 changed
Disks for B1, K1 and K3 Transmission 722.6 as of BT27.50-P-0013-01A
changed 02.09.02
details
14 Insert front freewheel The freewheel (92)
(92) and fit snap ring (91) must be installed in
direction of arrow
Continuing operation,
see: ?
Remove/install K1, K2 AR27.50-P-0621A
and K3

722.6 up to 722.6 as of
01.09.02 with 02.09.02 with
double sided single-sided
multiple-discs multiple-discs
BE27.51-P- Play in Number of 3 mm 2.70...3.10 2.40...2.80
1001-01B multiple- multiple- 4 mm 3.00...3.40 2.60...3.00
disc clutch discs 5 mm 3.30...3.70 2.80...3.20
K1
6 mm 3.60...4.00 2.90...3.30
Microsoft
Fig. 80: Identifying Assembly Tool (140 589 13 43 00)
Fig. 81: Identifying Clamping Device (208 589 00 21 00)
Insert and measure multi-disk pack K1 Thickness of steel multi-disks B1, K1 and K2 changed - AR27.51-P-0800-02A

disks B1, K1 and K2
changed
Modification notes
setting clearance
of multi-disk clutch

up to 01.09.02 with
double sided multi-
disks
BE27.51-P- Clearance of Number of 3 mm 2.70...3.10
1001-01B multi-disk multi-disks 4 mm 3.00...3.40
clutch K1 5 mm 3.30...3.70
6 mm 3.60...4.00
Microsoft
Fig. 83: Identifying External Plate Carrier/K1, Spring Washer
1. Assemble the disks for multi-disk clutch K1 in the sequence shown in the diagram and insert one at a
time.
2. Place pressing tool (078) on externally toothed plate (89c).
4. Using a feeler gage, measure the clearance "L" at three locations between the snap ring (90) and the
externally toothed plate (89c).
During the measuring procedure, the snap ring (90) must touch the upper contact surface of the groove in
5. Adjust clearance if necessary using appropriate snap ring (90).
Microsoft
Insert and measure multi-disk pack K1 - AR27.51-P-0800-02AA

as of 02.09.02 with
single-sided
multiple-discs
BE27.51-P- Play in Number of 3 mm 2.40...2.80
1001-01B multiple-disc multiple- discs 4 mm 2,60...3,00
clutch K1 5 mm 2.80...3.20
6 mm 2.90...3.30
Microsoft
1. Assemble and install the disks for the multi-disk clutch K1 in the sequence shown in the picture
individually.
Fig. 86: Identifying External Plate Carrier, Internally Toothed Plate
2. Mount pressure device (078) onto end disk (89c).

3. Compress the disk pack, to do so press the pressure device (078) together using a lever press up to
stop.
4. Use a feeler gauge to measure the clearance (L) at three points between the snap ring (90h) and end disk
(89c).
During the measuring procedure, the snap ring (90) must lie against the upper contact surface of the
groove in the external plate carrier (83a).
5. Use corresponding snap ring (90h) to adjust clearance (L) if necessary.
The snap rings (90) are available at sizes 2.6 mm, 2.9 mm, 3.2 mm, 3.5 mm, 3.8 mm and 4.1 mm.
Microsoft
Fig. 87: Identifying Pressure Device Onto End Disk
INSERTING AND MEASURING MULTIPLE-DISC PACK K2 THICKNESS OF STEEL DISCS B1,

K1 AND K2 REVISED ADDITIONAL DISC SPRING IN MULTIPLE-DISC PACK K2 - AR27.51-P-
0820-02A

disks B1, K1 and K2
revised
Additional disc spring in BT27.51-P-0003-01A
multiple-disc pack K2
Modification notes
25.8.98 Special new tool for Items 2 and 3
adjusting play incorporated for the first
time
30.3.99 New adjustment values
for multi-disc clutch
release clearance
Microsoft
Fig. 88: Identifying Presser (208 589 00 21 00)
Adjustment values - multiple-disc clutch

722.6 without 722.6 with
diaphragm spring diaphragm spring
BE27.51-P- Play in Number of 3 mm 1.40-1.80 2.30-2.70
1002-01B multiple- discs 4 mm 1.50-1.90 2.40-2.80
disc clutch 5 mm 1.70-2.10 2.50-2.90
K2
6 mm 1.80-2.20 2.70-3.10
Fig. 89: Identifying Outer Multiple-Disc Carrier/K2, Piston
Place new friction multiple-discs in ATF fluid for one hour before installing.
1. Put discs for multiple-disc clutch K2 together in the sequence shown in the illustration and insert
individually.
2. Mount presser (078) on outer multiple disc (105c).
3. Compress multiple-disc pack, using a lever press compress presser as far as the stop (then the marking
ring is still visible, see small arrow ).
4. Using a feeler gauge, determine the play "L" at three points between the snap ring (106) and outer
multiple-disc (105c).
During the measurement the snap ring (106) must contact the upper bearing surface of the groove in
the outer multiple-disc carrier.
5. Adjust with snap ring (106), if necessary.

Microsoft
Fig. 90: Identifying Presser On Outer Multiple Disc
DISMANTLING AND ASSEMBLING DRIVE SHAFT WITH CLUTCH K2 AND FRONT GEAR SET -
AR27.51-P-0825A
TRANSMISSION 722.6
Microsoft
Fig. 91: Identifying Drive Shaft With Clutch K2 And Front Gear Set Dismantle And Assemble
Components
Fig. 92: Identifying Snap Ring, Assembly Device
Modification notes
1.8.97 New assembly device Special tool for steps 8
and 13 modified
setting loose play
Microsoft
Disassembling
housing from torque
converter housing, fit on
2 Remove multiple-disk AR27.50-P-0621A
clutch K1, K2 and K3,
install
3 Remove snap ring (84b)
from the inner multiple-
disc carrier / clutch K1
with integrated front gear
set (84) and take off
hollow gear (84a)
Conversion from 18° to Transmission 722.6 BT27.50-P-0012-01A
23° teeth in front and rear
planetary gear set
4 Remove drive shaft with
clutch K2 (100)
Plain bearings of input Transmission 722.6 BT27.50-P-0002-02A
shaft converted to
antifriction bearings
5 Remove needle thrust
bearing (85)
from outer multiple-disc
carrier / clutch K2
7 Take out multiple-disc Inspect disks for
pack (105) scorch points and wear
8 Take out disk spring As of transmission no.
(107) 1596205
Additional disk spring in Transmission 722.6
multiple-disk set K2 BT27.51-P-0003-01A
9 Fit assembly device (076) Fig. 60
onto spring retainer (103)
Operate assembly
and press until snap ring
device with a lever press.
(104) is released (Fig. A)
11 Take out disc spring Further work
(102) and pull piston according to condition: ?
(101) out of outer Remove multiple-disk AR27.50-P-0721A
multiple-disc carrier brake B1 and oil pump,
install
Assembling
12 Install piston (101) in Inspect seals (101a
Microsoft
outer multiple-disc carrier and 101b), replace if

necessary.
The rounded edges of
the seals must point to the
outside.
13 Insert disk spring (102) Insert disk spring
and spring retainer(103) (102) with curved side
pointing toward spring
retainer (103).
Inspect seal (103a),
replace if necessary.
(076) on spring plate
(103) and press until the
groove of the snap ring is
exposed
16 Insert disk spring (107). As of transmission no.
1596205
Additional disk spring in Transmission 722.6 BT27.51-P-0003-01A
multiple-disk set K2
17 Insert multiple-disk set Pay attention to order AR27.51-P-0820-02A
(105) into outer multiple- of outer disks.
disk carrier and measure
Thickness of steel disks Transmission 722.6 BT27.51-P-0002-01A
B1, K1 and K2 modified
Survey of disks fitted as- Transmission 722.6 GF27.51-P-5200A
built configuration
18 Fit snap ring (106)
19 Insert axial needle Insert axial needle *BR00.45-Z-1007-06A
bearing (85) into inner bearing (85) with a little
multiple-disk carrier/K1 grease to prevent it
slipping.
20 Install drive shaft in inner
multiple-disc carrier/
clutch K1 with integrated
front gear set
21 Fit internally-geared Pay attention to
wheel (84a) installation position.
Further work: ?
Remove multiple-disk AR27.50-P-0621A
clutch K1, K2 and K3,
install
Microsoft
Repair materials
BR00.45-Z-1007-06A Grease A 001 989 37 51
DISASSEMBLE AND ASSEMBLE CLUTCH K3. - AR27.51-P-0830A
TRANSMISSION 722.6
Fig. 94: Identifying Clutch K3 Disassemble And Assemble Components
Modification notes
setting clearance
16.9.02 Multi-disks for B1, K1 Transmission 722.6 as of BT27.50-P-0013-01A
and K3 changed 02.09.02, refer to step 10.
Microsoft
Dismantling
1 Remove snap ring (44h)
from external plate
carrier
2 Remove multi-disk pack Check multi-disks for
(44g) and spring washer scorch marks and wear.
(44f) from external plate
carrier
(072) on spring plate
the snap ring (44e) is
exposed
4 Remove snap ring (44e)
5 Remove spring plate
(44d) and piston (44c)
from the external plate
carrier
Assemble
6 Install piston (44c) in the Check sealing ring
external plate carrier (44b) and replace if
necessary.
of the sealing ring must
point outwards
7 Insert spring plate (44d) Insert spring washer
with the curvature
towards the piston
(072) on spring plate and
tension until the groove
of the snap ring is
exposed
9 Insert snap ring (44e) The collar of the snap
ring must point towards
the multi-disk pack.
10 Insert spring washer (44f) Observe outer multi-
and multi-disk pack (44g) disk sequence Inserting
in the external plate and measuring clutch
carrier and measure pack K3: ?
Transmission 722.6 up to AR27.51-P-0830-01A
01.09.02
Play in multi-disk clutch *BE27.51-P-1003-01B
Microsoft
K3
Transmission 722.6 as of AR27.51-P-0830-01AA
02.09.02
Play in multi-disk clutch *BE27.51-P-1003-01B
K3
Thickness of friction and Transmission 722.6 BT27.51-P-0001-01A
steel multi-disks changed
Multi-disks for B1, K1 Transmission 722.6 as of BT27.50-P-0013-01A
and K3 changed 02.09.02
details
11 Insert snap ring (44h) For additional work,
see: ?
Install clutch K3 AR27.50-P-0810A

722.6 up to 722.6 as of
01.09.02 with 02.09.02 with
double sided single-sided multi-
multi-disks disks
BE27.51-P- Play in Number of 3 mm 2.30...2.70 2.30...2.70
1003-01B multi-disk multi-disks 4 mm 2.40...2.80 2.40...2.80
clutch K3 5 mm 2.50...2.90 2.50...2.90
Microsoft
Inserting and measuring multi-disk pack K3 Thickness of friction and steel multi-disks K3 changed - AR27.51-P-0830-
01A
Thickness of friction and BT27.51-P-0001-01A

steel multi-disks K3
changed
Modification notes
setting clearance
of multi-disk clutch

up to 01.09.02 with
double sided multi-
disks
BE27.51-P- Play in multi- Number of 3 mm 2.30...2.70
1003-01B disk clutch K3 multi-disks 4 mm 2.40...2.80
5 mm 2.50...2.90
Microsoft
Fig. 98: Identifying Measuring Multi-Disk Pack K3 Thickness Of Friction And Steel Multi-Disks
1. Assemble the disks for multi-disk clutch K3 in the sequence shown in the diagram and insert one at a
time.
2. Place pressing tool (078) on externally toothed plate (41a).
4. Using a feeler gage, measure the clearance "L" at three locations between the snap ring (44g) and the
externally toothed plate (41a).
During the measuring procedure, the snap ring (44g) must touch the upper contact surface of the groove
in the external plate carrier.
5. Adjust clearance if necessary using appropriate snap ring (44g).
Snap rings are available in thicknesses of 2.0, 2.3, 2.6, 2.9, 3.2, and 3.5 mm.
Microsoft
Inserting and measuring multiple-disc pack K3 - AR27.51-P-0830-01AA

as of 02.09.02 with
single-sided
multiple-discs
BE27.51-P- Play in Number of 3 mm 2,30...2,70
1003-01B multiple-disc multiple- discs 4 mm 2.40...2.80
clutch K3 5 mm 2.50...2.90
Fig. 100: Identifying Thrust Device(208 589 00 21 00)
1. Assemble and install the disks for the multi-disk clutch K3 in the sequence shown in the picture
individually.
Microsoft
Fig. 101: Identifying Multiple-Disc Pack K3
2. Mount pressure device (078) onto end disk (41a).

3. Compress the disk pack, to do so l press the pressure device (078) together using a lever press up to
stop.
4. Use a feeler gauge to measure the clearance (L) at three points between the snap ring (44g) and end disk
(41a).
During the measuring procedure, the snap ring (44g) must lie against the upper contact surface of the
groove in the external plate carrier (44a).
5. Use corresponding snap ring (44g) to adjust clearance (L) if necessary.
The snap rings (44g)are available at sizes 2.0 mm, 2.3 mm, 2.6 mm, 2.9 mm, 3.2 mm and 3.5 mm.
Microsoft
Fig. 102: Identifying Pressure Device Onto End Disk
FLUSH OUT OIL COOLER LINES AND OIL COOLER - AR27.55-P-0001A
TRANSMISSION 722.6 /7
Fig. 103: Flushing Out Oil Cooler Lines And Oil Cooler Components
Shown on model 168

Microsoft
Fig. 104: Flushing Out Oil Cooler Lines And Oil Cooler Components - Shown On Model 168
Extracting oil
1 Connect pump (2) to See: Fig. A
vacuum connection on
reservoir (3)
2 Attach plastic hose to
connection fitting (1) and
push all the way down
the oil filler pipe into the
oil pan
3 Actuate pump The extracted oil runs
into the reservoir (3).
Flushing
4 Connect pump (2) to See: Fig. B
pressure connection on
reservoir (3)
5 Fill reservoir (3) with
kerosene
6 Attach plastic hose to Ensure that the
connection fitting (1), kerosene can flow
screw onto one of the two through freely. Blow out
oil cooler lines using the oil cooler and oil cooler
appropriate connection line thoroughly with
piece (4) and flush out compressed air.
with kerosene
7 Connect the second Secure the plastic hose
plastic hose to the second on the connection fitting
oil cooler line and collect
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the escaping transmission with a hose clamp if

fluid necessary.
FLUSH OUT AUTOMATIC TRANSMISSION AND CONVERTER - AR27.55-P-0100A
TRANSMISSION 722.6
Fig. 106: Identifying Convertor Plate Locking Pin
Microsoft
Fig. 107: Identifying Oil Cooling Line Connection, Banjo Bolt
Fig. 108: Identifying Right Oil Cooling Line, Hose Clamp
Remove/install
Risk of injury to skin or Depressurize the hydraulic AS00.00-Z-0013-01A
eyes caused by hydraulic system completely before
fluid spraying out under starting any work on the
high pressure. Risk of system. Wear protective
poisoning caused by clothing and safety glasses.
swallowing hydraulic
fluid.
Microsoft
Risk of accident caused Secure vehicle to prevent it AS00.00-Z-0005-01A

by vehicle starting off by from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not grasp hot or rotating
burns during starting parts.
procedure or when
working near the running
engine
Risk of death caused by Align vehicle between the AS00.00-Z-0010-01A
vehicle slipping or columns of the lifting
toppling off of the lifting platform and position the
platform. four support plates at the
lifting platform support
points specified by the
vehicle manufacturer.
Notes on self-locking AH00.00-N-0001-01A
nuts and bolts
Before opening the
hydraulic system,
thoroughly clean the area
surrounding the
separation point. Even
the smallest dirt particles,
introduced into the
hydraulic components,
can lead to malfunctions
and a total failure of the
hydraulic system
1.1 Remove the rear section Vehicles with gasoline
of the engine engine except model 461
compartment paneling and 463
Model 129,202,208,210 AR61.20-P-1105AB
Model 140
Model 163 except AR61.20-P-1105GH
163.136/154/157
Model 163.136/154/157
Model 170 AR61.20-P-1105A
Model 171 AR61.20-P-1105V
Model 209, 203 with AR61.20-P-1105P
gasoline engine
Model 211 AR61.20-P-1105T
Model 219 AR61.20-P-1105TX
Model 215, 220 AR61.20-P-1105M
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Model 230 AR61.20-P-1105R

Model 240 AR61.20-P-1105H
1.2 Remove rear part of Vehicles with diesel engine
bottom sections of except model 461 and 463
soundproofing Model 140
Model 163 AR94.30-P-5400GH
Model 202.1 AR94.30-P-5300A
Model 209, 203 with diesel AR94.30-P-5300P
engine
Model 210 AR94.30-P-5300AB
Model 211 date service. AR94.30-P-5300T
Model 220 AR94.30-P-5300M
2 Unscrew drain plug from The transmission oil
the transmission oil pan should have an operating
and drain transmission oil temperature of 80 °C.
*BA27.10-P-1001-03A
3 Detach transmission oil Caution: when
pan and install a new removing the transmission
transmission oil filter oil pan, approx. 2.5 liters of
transmission oil will still be
in the transmission oil pan.
4 Mount transmission oil Install new gasket.
pan *BA27.10-P-1002-03A
5 Detach clamps for right Model 163, 171, *BA27.55-P-1004-01A
oil cooling line (2) from 211, 219, 220, 461, 463
engine oil pan Model 199, 203, *BA27.55-P-1003-01B
209, 215, 230
6 Unscrew banjo bolt (3) Model 163, 171, *BA27.55-P-1002-01A
from connection (1) on 211, 219, 220, 461, 463
right oil cooling line (2) Model 199, 203, *BA27.55-P-1002-01B
209, 215, 230
7 Join connection fitting Remove the connection
(4) with an approx. 1.5 fitting (4) from the l hand
meter long hose using a pump.
hose clamp (5) Fig. 5
8 Mount banjo bolt (3) and
oil cooling line (2) to
connection fitting (4)
9 Hold hose into a bucket The bucket should have
with a scale on it a capacity of 10 liters.
10 Unlock cap (93) Break off plate (93a)
using a suitable tool and
press out locking pin (93b)
Microsoft
remaining in cap (93)

downwards.
11 Detach cap (93) from oil
filler pipe
12 Fit funnel to oil filler The entire flushing
pipe and pour 5 liters of procedure requires 14 liters
oil into transmission of transmission oil.
Fig. 2
Flushing
An assistant is required
for the flushing
procedure
13 Start the engine and drain Always observe work
transmission oil via the procedure and operating
hose into the bucket fluid specifications,
otherwise transmission will
be damaged.
14 Once 3 liters of
transmission oil are in the
bucket stop the engine
immediately
15 Pour in 3 liters of
transmission oil
16 Repeat flushing process
twice
17 Add remaining Model 129, 140, 163, 170, AR27.00-P-0101A
transmission oil (3 liters) 202, 208, 210, 211, 215,
and check transmission 220, 230, 240, 461, 463
oil level except 463.270/ 271
Model 171 AR27.00-P-0101V
Model 203, 209 AR27.00-P-0101P
Model 219 AR27.00-P-0101TZ
Model 463.270/271 AR27.00-P-0101GX
order
19 Carry out engine test run,
checking the
transmission for function
and oil leaks
OIL PAN, AUTOMATIC TRANSMISSION

Number Designation Transmission Transmission Transmission Transmission
722.6 except 722.628 722.648 722.649
Microsoft
722.628/
648/649
BA27.10- Oil drain plug Nm 20 20 20 22
P-1001- to oil pan
03A
BA27.10- Bolt, oil pan Nm 8 8 8 8
P-1002- to
03A transmission Angle° - - - -
housing
TRANSMISSION, OIL COOLER

722.660/ 661 in 722.662/ 722.6 in model
model 163 663/666/ 673/674 171
in model 163
BA27.55-P- Banjo bolt or Stage 1 Nm 20 20 5
1002-01A union nut, oil
cooler line to
torque
converter and Stage 2 Angle° - - 95
transmission
housing
BA27.55-P- Bolt, clamp of Nm 8 8 8
1004-01A oil cooler line
to oil pan

Transmissions
Transmission Transmission Transmission 722.610/
722.6 in 722.643 in 722.6 in 611/630/
Number Designation model 211 model 219 model 220 637/638/ 645
BA27.55- Banjo bolt or Stage 1 Nm 5 20 5 20
P-1002- union nut, oil
01A cooler line to
torque
converter Stage 2 Angle° 95 - 95 -
and
transmission
housing
BA27.55- Bolt, clamp of oil Nm 8 8 8 8
P-1004- cooler line to oil pan
01A

Microsoft
722.648 722.649 except 722.695

in model
230.477
BA27.55-P- Banjo bolt, Stage 1 Nm 20 5 5
1002-01B transmission
oil line to
transmission Stage 2 Angle° - 95 90
housing
BA27.55-P- Bolt, oil cooler Nm - 11 11
1003-01B line to engine
oil pan
Fig. 109: Identifying Funnel (126 589 12 63 00)
REMOVING AND INSTALLING IGNITION LOCK CONTROL CABLE - AR27.60-P-0122G
TRANSMISSION 722.6 in MODEL 170 as of 1.12.99
Microsoft
Fig. 111: Identifying Ignition Lock Control Cable Remove/Install Components - Model 170
Removing, installing
1 Disconnect ground cable AR54.10-P-0003A
of battery
2 Remove ashtray at front AR68.20-P-2410G
of center console
3 Remove cover below AR68.10-P-1500G
instrument panel (left)
4 Press locking tabs (1a) Installation: Switch
together and push ignition lock to position
ignition lock control "0".
cable (1) out of ignition / Function test:
starter switch (N73) in
direction of arrow  It must only be
possible to move the
selector lever out of
position "P" when
the ignition lock is in
position "2" and the
brake pedal is
depressed.
 It must only be
possible to withdraw
the ignition key
when the selector
lever is in position
"P".
Microsoft
5 Unclip ignition lock Press locking tab (1b),

control cable (1) from twist coupling (1c) through
electronic selector lever 90° in direction of arrow
module (N15/5) and pull off ignition lock
control cable (1).
6 Remove ignition lock
control cable (1) from
dashboard
order
REMOVING AND INSTALLING WIRE CABLE / TRANSMISSION FOR PARKING SHIFT LOCK
ON TRANSMISSION - AR27.60-P-0500-05B
For removal and installation, move selector lever or range selector lever to position "P" and, with control
cable / gears removed, leave in position "P".
Removing
1. Turn cable/transmission (80) on transmission counterclockwise and remove.
Fig. 112: Removing Cable/Transmission
Installation
2. Install cable/transmission (80) and turn clockwise
After installation, adjust cable for parking shift lock and check for proper operation.
Microsoft
Fig. 113: Installing Cable/Transmission
REMOVE/INSTALL FLOOR SELECTOR - AR27.60-P-0900B
TRANSMISSIONS 722.6
in model 129,140,
163 up to 31.8.99,
170 up to 30.11.99,
202, 208, 210 up to 30.6.99
Shown on floor shift with W/S switch
Fig. 114: Identifying Floor Selector Remove/Install Components - Shown On Floor Shift With W/S
Switch
Microsoft
Remove/Install
1 Disconnect shift rod from Remove retaining
intermediate lever (97) clip. If adjusting: ?
Adjust shift rod. AR27.60-P-0980B
2 Remove center console Model 140, 129 ra68001400200x
AR68.20-P-2010G Model 170
Model 202 AR68.20-P-2000E
Model 208 AR68.20-P-2000K
Model 210 AR68.20-P-2000F
3.1 Remove insulation mat Model Series 163
4 Unscrew hexagon socket *BA27.60-P-1001-02A
bolts (40)
5 Unplug connectors From gear
identification switch
(S16/10), reverse lamp
switch (S16/10s2) and
R/P lock electromagnetic
actuator (Y66/1).
6 Remove floor shift Disassemble and AR27.60-P-0920B
assemble floor shift
according to condition.
Installation: Check
gasket (39) for correct
installation position and
condition, replace if
necessary.
7 Install in the reverse After installing the
order floor shift, read out and
erase fault code using
HHT, refer to DM
Chassis Volume 1 -
Index 0.
Tightening torques for floor shift

BA27.60-P-1001-02A Bolt, floor selector to Nm 6
body
REMOVING AND INSTALLING ELECTRONIC SELECTOR LEVER MODULE (ESM) - AR27.60-P-

0901B
TRANSMISSION 722.6
Microsoft
in MODEL 163 as of 1.9.99,
170 as of 1.12.99,
202, 208, 210 as of 1.7.99
Fig. 115: Identifying Electronic Selector Lever Module Remove/Install Components - 170 As Of 1.12.99,
Removing, installing
1 Unhook shift rod at If performing any
intermediate lever (3) by adjustment work: ?
removing the clip
locking device Adjust shift rod. AR27.60-P-0980B
2 Remove center console Models 140, 129. ra68001400200x
Model 170. AR68.20-P-2310G
Model 202. AR68.20-P-2310E
AR68.20-P-2000E
Model 208 AR68.20-P-2310K
AR68.20-P-2000K
Model 210. AR68.20-P-2310F
AR68.20-P-2000F
Model 463. AR68.20-P-2000A
Model 163. AR68.20-P-2000GH
3 Remove insulation mat Model 163.
4 Unclip ignition lock Press locking tab (1b),
control cable (1) from twist coupling (1c)
electronic selector lever through 90° in direction of
module (N15/5) arrow and pull off ignition
Microsoft
lock control cable (1).

Installation: Switch
ignition lock to position
"0".
Function test:
 It must only be
possible to move the
selector lever out of
position "P" when
the ignition lock is
in position "2" and
the brake pedal is
depressed.
 It must only be
possible to
withdraw the
ignition key when
the selector lever is
in position "P".
5 Unscrew Allen bolts (2) *BA27.60-P-1001-02A
6 Disconnect selector
lever position plug
connector (5)
7 Remove electronic Cannot be
selector lever module disassembled.
(N15/5) Installation: Check
gasket (4) for correct
installed position and
condition, replace if
necessary.
8 Install in the reverse After installing the
order electronic selector lever
module, read out the fault
memory with STAR
DIAGNOSIS.

BA27.60-P-1001-02A Bolt, floor shift to body Nm 6
ADJUST SHIFT LOCK - AR27.60-P-0910A
TRANSMISSION 722.60/610,
Microsoft
722.610/611 up to 30.11.00,
722.612 /613 /62 (except, 722.626 /628),
722.630 up to 30.11.00,
722.631 /66 /645
Shown at center shifter console of model 140
Fig. 116: Identifying Adjust Shift Lock - Shown At Center Shifter Console Of Model 140
Adjust
1 Move selector lever into The selector lever
neutral position must make contact with
the shift gate (arrow).
2 Apply battery voltage of Use the connecting Fig. 118
11 V up to 14 V to the cable from the
reverse/parking lock electrical connection kit.
valve (Y66/1)
3 Loosen bolt (111)
4 Adjust gap (A) between The adjusting screw *BE27.60-P-1001-01A
locking lever (125) and (126) must contact the
disk cam (124) using bracket (117) with no gap
adjuster screw (126)
5 Tighten screw (111) *BA27.60-P-1003-02A
Shift lock test values

Microsoft
BE27.60-P-1001- Gap dimension "a" mm 0,2

01A between locking
Figure see AR27.60-P-0910A
lever and disk cam

BA27.60-P-1003-02A Bolt for bracket to shift Nm 3.5
lock on bearing bracket
upper section
Fig. 117: Identifying Electrical Connection Set (201 589 00 99 00)
Fig. 118: Identifying Electrical Connector Set (201 589 00 99 00)
DISASSEMBLING AND ASSEMBLING FLOOR SHIFT - AR27.60-P-0920B
TRANSMISSION 722.60 /610 /611 /612 /613 /62 /630 /631 /66 (except, 722.626 /628)
Not with one-touch shift
Microsoft
Fig. 119: Identifying Floor Shift Components - Without One-Touch Shift (1 Of 2)
Fig. 120: Identifying Floor Shift Components - Without One-Touch Shift (2 Of 2)
Modification notes
1.7.97 Remove sleeve Step 14a, included for
Microsoft
first time
Disassembly, assembly
1 Remove selector lever AR27.60-P-0920-01A
handle (108)
2 Unclip trim (109)
(arrows)
3 Unclip cover (110)
(arrows)
4 Unscrew bolt (111) *BA27.60-P-1003-02A
5 Move selector lever (112)
into position "D"
6 Unclip upper section of
bearing bracket (113)
(arrows)
7 Pull carrier (129) out of
upper section of bearing
bracket and remove
sliding cover (130)
8 Take off gear display
(114)
9 Disconnect gear Installation: Move
identification switch selector lever into
(S16/10) position "1"
In the installed position
of the transmission range
recognition switch
relative to shift shaft,
driver (115) must be
positioned at the rear in
direction of travel
(arrow).
10 Take off shift shaft (116) Installation: Insert *BR00.45-Z-1001-06A
complete with components only pre-
intermediate lever (97) assembled into bottom
and bracket with shift part of bearing bracket
lock (117) (113a) and grease bearing
points.
11 Pull shift shafts (116) out
of bracket with shift lock
12 Detach selector lever Spring (112d) may
with clevis (112a) by jump out.
removing retainer (112b)
and pulling out pin (112c)
Microsoft
Selector lever brazed Transmission 722.6 as of BT27.60-P-0002-01A

01.05.96
13 Unbolt shift detent (120) Installation: Grease *BR00.45-Z-1001-06A
ball.
14 Remove bearing bush on Inspect bearing bush
left (122); take pin (127) for wear, replace if
out of shift shaft with a necessary.
press for this step
15 Separate shift shaft (116) Installation: Grease
with idler lever (97) from pin lightly before
sleeve (137) by removing installing it in the shift
pin (127) shaft.
Center shift modified BT27.60-P-0001-01A
16 Remove right bearing Inspect bearing bush
bush (121) from bracket for wear, replace if
necessary.
17 Take off supporting lever
(119); release spring
(118) and take off circlip
(119a) for this step
18 Take shift gate (128) off *BA27.60-P-1002-02A
bottom part of bearing
bracket; unscrew hexagon
socket bolts (123) for this
step
19 Reassemble in opposite
order
20 Set play at shift lock AR27.60-P-0910A
Inspection data of shift lock

BE27.60-P-1001- Size of gap "a" mm 0.2
01A between locking
lever and cam plate Figure see AR27.60-P-0910A
Tightening torques of floor-mounted shift

BA27.60-P-1002-02A Bolt of shift gate to Nm 6
bottom part of bearing
bracket
BA27.60-P-1003-02A Bolt of bracket of shift Nm 3.5
lock to top part of bearing
bracket
Microsoft
Fig. 121: Identifying Electrical Connection Set (201 589 00 99 00)
Repair materials
BR00.45-Z-1001-06A Long-life grease A 000 989 63 51
Removing and installing selector lever handle - AR27.60-P-0920-01A
Remove
1. Loosen clamp (3) by turning counter-clockwise (arrow A).

2. Pull selector lever handle (1) off selector lever (4).
Install
3. Push selector lever handle (1) onto the selector lever (4) and tighten the clamping piece (3) in clockwise
direction (arrow B).
Fig. 122: Identifying Selector Lever Handle Remove/Install Components
ADJUSTING WIRE CABLES FOR PARKING LOCK INTERLOCK - AR27.60-P-0965B
Microsoft
722.620 ## as of 1681,
722.621 ## as of 1977,
722.622 ## as of 16287,
722.623 /624 /625 /626 /627 /628 /629 /63 /66 /69
Fig. 123: Identifying Wire Cables For Parking Lock Interlock Components
Modification notes
15.10.97 Sequence of work steps
revised
The selector lever must be in

position "P" for all
adjustment work.
Adjusting wire The wire
cable/steering lock cable/transmission must be
installed to adjust the wire
cable/steering lock.
1 Pretension spring on
adjusting button (79a)
2 Turn key in steering lock to
position "0"
3 Adjust wire cable/steering
lock (79) by pressing
Microsoft
(arrow)
Adjusting wire
cable/transmission
4 Pretension spring on
5 Turn key in steering lock to
position "0"
6 Adjust wire
cable/transmission (80) by
pressing the adjusting button
(80a) (arrow) Figure A
ADJUSTING SHIFT ROD - AR27.60-P-0980B
TRANSMISSION 722.6 in MODEL 129, 140, 163, 170, 202, 208, 210
Fig. 124: Adjusting Shift Rod
Adjust
Vehicle must be Position vehicle on the
horizontal and standing four column lifting
on its wheels platform.
Microsoft
1 Move selector lever to Have an assistant hold

position "D". the selector lever in
position "D" for the entire
duration of the
adjustment work.
2 Mount head (98) on Pliers Fig. 8
intermediate lever (97)
and secure with clip
3 Guide shift rod (63) into Pliers Fig. 8
head, attach at selector
lever (33) and secure with
clip
4 Tighten bolt (99) Press against rod head
(98) to tighten.
Do not twist shift rod
(63) or rod head (98).
Do not move selector
lever (33) out of position
"D".
*BA27.60-P-1001-04A
TIGHTENING TORQUES FOR SHIFT ROD

BA27.60-P-1001- Bolt in rod head M8 X 10 Nm 12
04A
REMOVING AND INSTALLING WIRE CABLE FOR PARKING LOCK INTERLOCK - AR27.60-P-
1000B
722.620 ## as of 1681,
722.621 ## as of 1977,
Microsoft
722.622 ## as of 16287,
722.623 /624 /625 /626 /627 /628 /629 /63 /66 /69
Fig. 126: Identifying Wire Cable For Parking Lock Interlock Remove/Install Components
Removing and installing

wire cable/ steering lock
1 Remove cover below left of ra68001400150x
instrument panel
2 Unhook wire cable/steering Installation :
lock (79) by pressing in the Position key in steering
locking tongues and at the lock in position "1"
same time pressing (arrows)
against the steering lock
(figure A)
3 Remove stop lamp switch AR42.10-P-0040A
4 Unhook wire cable/steering
lock (79) at the release lever
(77) (arrow) (figure B)
5 Compress locking device
(arrows) and at the same time
push the wire cable/steering
lock upwards out of the
mount on the pedal bearing
bracket (figure C)
6 Remove wire cable/steering
lock
7 Install in reverse order
Microsoft
8 Adjust wire cables for parking AR27.60-P-0965A

lock interlock
Removing wire
cable/transmission
9 Remove cover below left of ra68001400150x
instrument panel
10 Pull off entrance strip
upwards
11 Remove A-pillar footwell
cover
12 Unscrew accelerator pedal
from floor panel
13 Remove driver side floor Do not fold up floor
lining complete carpet, foamed
insulating material
cracks.
14 Remove air duct for rear
compartment heating
15 Unhook wire
cable/transmission (80) at
release lever (77) (arrow)
(figure B)
16 Compress locking device
(arrows) and at the same time
push the wire
cable/transmission upwards
out of the mount on the pedal
bearing bracket (figure C)
17 Turn wire cable/transmission To install and AR27.60-P-0500-05B
(80) counterclockwise and remove, position
pull off (figure D) selector lever or range
selector lever in
position "P" and leave
in position "P" when
wire cable/
transmission is
removed.
Installation :
Attach wire cable/
transmission and turn
clockwise (figure E)
18 Remove rubber boot on tunnel
19 Open cable straps behind Installation :
cover on left of tunnel and Attach wire cable/
remove wire transmission in the
Microsoft
cable/transmission bracket on the jacket

tube
20 Install in reverse order
21 Adjust wire cables for parking AR27.60-P-0965A
lock interlock
Microsoft

Testing Repair

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Testing Repair

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1999 Mercedes-Benz SLK230

1998-2004 TRANSMISSION Automatic Transmission - Testing & Repair - 170 Chassis

Automatic Transmission - Testing & Repair - 170 Chassis

TESTING & REPAIR

Transmission 722.6 in MODEL 461, 463 (except, 463.270 /271)

Fig. 1: Identifying ATF Level Components

Adding transmission oil

(93a) by breaking off the plate

10 Warm up transmission oil

and, with engine running,

for Operating 10A 0236-10A 10A

Fig. 2: Identifying Funnel (126 589 12 63 00)

Fig. 3: Identifying Dipstick (140 589 15 21 00)

Fig. 4: Identifying Filling Pipe (140 589 49 63 00)

Fig. 5: Identifying Hand Pump (210 589 00 71 00)

Commercially available tools

system, Compact Passenger Car

REMOVE/INSTALL TRANSMISSION WITH TORQUE CONVERTER - AR27.10-P-0500B

TRANSMISSION 722.6 in MODELS 129, 140, 170, 202, 208, 210

Fig. 6: Identifying Transmission With Torque Converter Components

from radiator Model 140 with engine 606

Risk of accident Secure vehicle to prevent it from AS00.00-Z-0005-01A

Oil pan, automatic transmission

Front axle shaft

Number Designation Model 129 Model 140 Model 170

Fig. 7: Identifying Grab Handle (168 589 00 62 00)

Fig. 8: Identifying Pliers (210 589 00 37 00)

Commercially available tools

Disconnecting and connecting plug connector - AR27.10-P-0500-01A

1. Unscrew bolt (62a) .

Heat shield (62) not installed on model 463.

Fig. 9: Identifying Heat Shield And Bolts

Replace O-ring of electrical connector (26).

5. Install in the reverse order.

Fig. 10: Identifying Pilot Bushing And Electrical Connector

FASTEN TRANSMISSION TO ASSEMBLY STAND SUPPORT PLATE FOR MOUNTING

Only for transmission 722.626

Fig. 11: Identifying Assembly Stand (140 589 34 63 00)

Fig. 12: Identifying Support Plate (140 589 34 63 00)

1. Bolt support plate (071) to assembly stand (070).

Fig. 13: Identifying Support Plate & Assembly Stand

Fig. 14: Identifying Transmission & Support Plate

REMOVE/INSTALL ELECTROHYDRAULIC CONTROLLER UNIT (TRANSMISSION

TRANSMISSION 722.6 in MODEL 461, 463 (except 461.331, 463.270 /271)

Fig. 15: Identifying Electrohydraulic Controller Unit Components

beyond the reach of the

to do this, unscrew oil ring.

Oil pan, automatic transmission

Electrohydraulic controller unit

Insert selector valve into driver of detent plate - AR27.19-P-0200-01A

DISASSEMBLE AND ASSEMBLE ELECTROHYDRAULIC CONTROL UNIT - AR27.19-P-0220A

Transmission 722.6 in MODELS 461.302 /332 /342 /345,

Shown on the electrohydraulic control unit in model 163

24.9.97 Caps for solenoid valves, Step 1 BT27.19-P-0003-01A

one side and remove electric

Electrohydraulic control unit

Fig. 18: Identifying Pliers (606 589 00 37 00)

REPLACE PILOT BUSHING IN THE ELECTROHYDRAULIC CONTROL UNIT - AR27.19-P-0230A

Fig. 19: Identifying Electrohydraulic Control Unit Components

Model 230 AR61.20-P-1105R

ELECTROHYDRAULIC CONTROL UNIT

Number Designation 722.660/661/662 /663/666/674 2/663/666/674

REMOVE/INSTALL TORQUE CONVERTER - AR27.20-P-0500-01B