AR28.10-P-1004SYZ Disassemble, assemble and seal MODEL /18, /28 with TRANSMISSION 722.9

Transcription

1 AR28.10-P-1004SYZ Disassemble, assemble and seal MODEL /18, /28 with TRANSMISSION Collar nut 2 Output flange 3 Radial shaft seal 4 Intermediate housing 5 Automatic transmission 6 Circlip 7 Grooved ball bearing 8 Bolts 9 Rear cover 10 Circlip 11 Output shaft 12 Oil filler plug 13 Connecting bolt 14 Ring gear with intermediate shaft 15 Needle roller bearing 23 Oil drain screw 24 Transfer case 4 Intermediate housing 5 Automatic transmission 14 Ring gear with intermediate shaft 16 Planet carrier 17 Bolts 18 Drive pinion of transfer case 19 Differential side gear of front axle propeller shaft 20 Radial shaft seal 21 Shim 22 Guide sleeve P P Copyright Daimler AG 2/2/17 G/01/08. This WIS printout will not be recorded by the update service. Page 1

2 5 Automatic transmission 20 Radial shaft seal P Remove/install Important repair information 1.1 Move DIRECT SELECT gear selector switch Model 221 to "N" position 1.2 Move selector lever into position "N" The transfer case (24) cannot be replaced separately, it must be replaced complete with the automatic transmission (5). The following components of the transfer case (24) can be replaced separately: Output flange (2) Radial shaft sealing ring (3) Grooved ball bearing (7) Rear cover (9) Output shaft (11) Ring gear (14) Needle roller bearing (15) Planet carrier (16) Radial shaft sealing ring (20) Shim (21) Guide sleeve (22) In the event of damage to the bearings on the bevel pinions or differential side gears (18, 19) or damage to the intermediate housing (4) and basic housing the transfer case (24) with automatic transmission (5) must be replaced as a unit. 2 Detach ground lines from the batteries Model 221 AR54.10-P-0003SX AR54.10-P-0003CW Notes on battery AH54.10-P A 3 Remove hot film mass air flow sensor with gasoline engine AR07.07-P-1453CV 4 Remove air duct housing with gasoline engine AR09.20-P-0080CV 5 Secure vehicle on lifting platform Model 221 AR00.60-P-0100SX 6.1 Remove diesel particulate filter Model 221 with diesel engine AR14.40-P-1000SXI 6.2 Remove right catalytic converter Model 221 with gasoline engine AR49.10-P-7100SX 6.3 Detach rear reinforcement brace from frame floor assembly 7 Remove heat shields above propeller shaft 8 Separate exhaust system at flange connection upstream of the center muffler 9 Support automatic transmission (5) with transmission jack and transmission platform *BA61.10-P H 10 Remove rear engine crossmember Model 221 AR22.10-P-1180SW AR22.10-P-1180CW Notes on bolted connections with self tapping AH00.00-P SF screws 11 Detach flexible coupling from transfer case Model 221 AR41.10-P-0050SYZ (24) and propeller shaft AR41.10-P-0050CW Copyright Daimler AG 2/2/17 G/01/08. This WIS printout will not be recorded by the update service. Page 2

3 12 Lower the automatic transmission (5) 13 Remove front axle gear propeller shaft When replacing the radial shaft sealing ring (20) or during repair work on the automatic transmission (5). Model Remove heat shields on the vehicle underbody in the area of the transfer case (24) 15 Detach stiffening bridge on underfloor Model 221 AR41.10-P-0070SYZ AR41.10-P-0070CWX *BA61.10-P G *BA61.10-P G 16 Drain oil out of transfer case (24); to do so, Installation: Replace sealing ring. remove oil drain screw (23) from intermediate housing (4) *BA28.10-P E 17.1 Remove intelligent servo module (ISM) Model 221 AR27.19-P-0550SX Only to remove the ring gear (14) Detach shift rod on range selector lever of automatic transmission (5) Only to remove the ring gear (14). Disassemble/assemble Installation: Replace securing clamp of shift rod. 18 Detach collar nut (1) from output flange (2) Installation: Replace collar nut (1) and secure after tightening. 19 Detach output flange (2) from output shaft Use puller if output flange (2) is (11) seized. Check output flange (2) for wear and damage and replace if necessary. 20 Remove radial shaft sealing ring (3) from In the event of leakage or when replacing the rear cover (9) grooved ball bearing (7). Do not damage seat of radial shaft sealing ring (3). Check the seat of the radial shaft sealing ring (3) for wear and damage; replace the rear cover (9) in the event of complaints. Installation: Use drift to hammer in radial shaft sealing ring (3) until it abuts with the rear cover (9). 21 Remove rear cover (9); to do this, unscrew Installation: In order to avoid leaks, the bolts (8) and remove rear cover (9) sealing surfaces on the intermediate housing (4) and rear cover (9) must be free from oil and grease. Loctite 7200 Sealant 22 Remove grooved ball bearing (7); to do this, The grooved ball bearing (7) only has to remove circlip (6) from rear cover (9) and be replaced in the event of complaints or press out grooved ball bearing (7) damage. 23 Remove circlip (10) and remove output shaft Check circlip (10) for deformation and (11) damage and replace if necessary. Installation: Check circlip (10) for correct seat in the planet carrier (16). 24 Using the assembly tool move the When removing the ring gear (14). automatic transmission (5) into position "P" at the range selector shaft *BA28.10-P E * * * * * *BA28.10-P E *BR00.45-Z A *BR00.45-Z A * Detach needle roller bearing (15) from ring Check needle roller bearing (15) for wear gear (14) and damage and replace if necessary. Copyright Daimler AG 2/2/17 G/01/08. This WIS printout will not be recorded by the update service. Page 3

4 26 Unscrew connecting bolt (13) Installation: The connecting bolt (13) must always be replaced. *BA28.10-P E 27 Remove ring gear (14) using extraction Pay attention to correct seat of AR28.10-P SYZ tool extraction tool on ring gear (14). * Remove planet carrier (16) Installation: Press on the ring gear (14) by hand and pull in using a new connecting bolt (13). 29 Unscrew bolts (17) and remove intermediate Installation: In order to avoid leaks, the housing (4) sealing surfaces on the intermediate housing (4) and automatic transmission (5) must be free from oil and grease. Installation: Before attaching the intermediate housing (4), the assembly sleeve must be removed from the differential side gear (19). Loctite 7200 Sealant 30 Remove differential side gear (19) Installation: When installing the 31 Remove drive pinion (18) differential side gear (19) the assembly sleeve must be used so that the radial shaft sealing ring (20) of the differential side gear (19) in the transmission housing is not damaged. Installation: Pay attention to the correct seat of the assembly sleeve on the differential side gear (19). 32 Remove radial shaft sealing ring (20) of When prying off the radial shaft sealing differential side gear (19) using a suitable ring (20), do not rest the tool against tool automatic transmission (5) without a rag, otherwise the sealing surface on the automatic transmission (5) will be damaged (see picture 3). Installation: Replace the radial shaft sealing ring (20) and make sure that it is installed at the correct position (see enlarged detail in picture 3). Installation: Hammer radial shaft sealing ring (20) into transmission housing using drift. Make sure that the radial shaft sealing ring (20) is seated correctly in the automatic transmission (5). 33 Remove guide sleeve (22) and shim (21) The basic dimension must be determined from output shaft (11) before repair work on the automatic transmission (5): Measure axial play between park pawl gear and grooved ball bearing. 34 Assemble in the reverse order Clean LU cleaner Loctite 7200 *BA28.10-P E *BR00.45-Z A *BR00.45-Z A * * AR27.50-P SYZ * *BR00.45-Z A *BR00.45-Z A 35 Clean all parts of the transfer case (24) LU cleaner *BR00.45-Z A thoroughly 36 Install in the reverse order 37 Prefill transfer case (24) with a prefill quantity The transfer case (24) is connected to AR27.00-P-0270SYZ of 0.7 l transmission oil and fill automatic the oil circuit of the automatic transmission transmission (5) with transmission oil (5). The oil level can therefore only be checked and corrected via the automatic transmission (5): Fill the automatic transmission (5) with AR27.00-P-0100W transmission oil. Copyright Daimler AG 2/2/17 G/01/08. This WIS printout will not be recorded by the update service. Page 4

5 *BA28.10-P E Danger! Risk of accident caused by vehicle starting Secure vehicle to prevent it from moving by off by itself when engine is running. Risk of itself. injury caused by contusions and burns Wear closed and snug-fitting work clothes. during starting procedure or when working near the engine as it is running Do not touch hot or rotating parts. 38 Carry out engine test run and check the automatic transmission (5) and transfer case (24) for leaktightness and function AS00.00-Z A Frame floor assembly Number Designation Model 221 BA61.10-P G Nut, front stiffening bridge to frame floor Nm 40 assembly BA61.10-P G Bolt, rear stiffening bridge to frame floor Nm 23 assembly Frame floor assembly Number Designation Model 204 BA61.10-P H Bolt, rear reinforcement brace to frame floor Nm 24 assembly Transfer case complete Number Designation Model Model /09/ /18 28/29/98/ 99 BA28.10-P E Bolt, intermediate housing to transmission Nm housing BA28.10-P E Bolt, transmission cover to intermediate Nm 8 8 housing BA28.10-P E Bolt, ring gear to output shaft which is Stage 1 Nm divided into two Stage BA28.10-P E Collar nut, output flange to output shaft Nm BA28.10-P E Oil filler screw to intermediate housing Nm BA28.10-P E Oil drain screw to intermediate housing Nm Puller Drift Connecting piece Assembly tool Copyright Daimler AG 2/2/17 G/01/08. This WIS printout will not be recorded by the update service. Page 5

6 Extraction tool Assembly sleeve Drift Pin wrench Wrench socket Parallel support Auxiliary repair materials Number Designation Order number BR00.45-Z A Sealant A BR00.45-Z A Loctite 7200 Henkel Loctite Deutschland GmbH Arabellastrasse München Germany Tel Fax BR00.45-Z A LU cleaner Adolf Würth GmbH & Co. KG Reinhold-Würth-Str Künzelsau-Gaisbach Germany Tel Fax Copyright Daimler AG 2/2/17 G/01/08. This WIS printout will not be recorded by the update service. Page 6