NAG1 Transmissions
NOTE:Be aware of Sprinter NAG1 characteristics:
^ Automatic Transmission Fluid (ATF) requires replacement at every second maintenance interval 96,000 km (60,000 mi).
^ Special ATF available from Mopar, pin 05127382AB.
^ Drain plugs in the oil pan as well as in the torque converter.
^ Dipstick, only use special tool 8863B to determine the fluid level.
^ The bell housing has a special geometry fitting 0M612 and 0M647 engines.
^ Several clutch discs are unique for Sprinter.
^ The Transmission Control Module is fine tuned for the use of the special ATF based on a commercial vehicle duty cycle.
^ Identification label on the side of the housing has a different placement and format.
CAUTION:
Using a non-approved ATF may result in shifting concerns and clutch discs may suffer from premature wear resulting in a non-warrantable failure of the transmission.
1. Remove fluid using approved Team PSE Automatic Transmission Fluid X-changer or equivalent.
2. Remove torque converter (keep with unit).
3. Measure input shaft end play.
4. Stand the transmission upright on the converter housing. Be sure to use suitable spacers between the bench surface and the converter housing since the input shaft may protrude past the front surface of the housing.
5. Loosen electrical connector guide bushing and remove from transmission housing.
6. Remove transmission oil pan.
7. Remove oil filter.
8. Unscrew Torx socket bolts and remove electrohydraulic unit.
9. Place the transmission in PARK to prepare for the removal of the output shaft nut.
10. Remove the nut holding the propeller shaft flange to the output shaft and remove the flange.
11. Remove the transmission rear oil seal with a suitable slide hammer and screw.
12. Remove the transmission output shaft washer. Be sure to tag the washer since it is very similar to the geartrain end-play shim and they must not be interchanged.
13. Remove the transmission rear output shaft bearing retaining ring.
14. Position Bearing Remover tool 9082 over the inner race of the output shaft bearing.
15. Slide the collar on Bearing Remover tool 9082 downward over the fingers of the tool and remove the output shaft bearing.
16. Remove the geartrain end-play shim from the output shaft. Be sure to tag the shim since it is very similar to the output shaft washer and they must not be interchanged.
17. Remove the bolts holding the transmission housing to the converter housing from inside the converter housing.
18. Stand the transmission upright on the converter housing. Be sure to use suitable spacers between the bench surface and the converter housing since the input shaft may protrude past the front surface of the housing.
19. Remove the remaining bolts holding the transmission housing to the converter housing.
20. Remove the transmission housing from the converter housing.
21. Remove output shaft with center and rear gear set and clutch K3.
22. Remove thrust needle bearing and thrust washer.
23. Remove input shaft with clutch 1(2 and front gear set.
24. Remove clutch K1.
25. Unscrew Torx socket bolts and remove oil pump. Screw two opposed bolts into the oil pump housing and press the oil pump out of the converter housing by applying light blows with a plastic hammer.
26. If transmission is determined to be greater than 70% failed follow steps 27 through 30. If transmission is determined to be less than 70% failed, refer to the service information available in TechCONNECT or the appropriate service manual in Section 21 for detailed repair instructions.
27. Place rear seal and thrust washer in transmission pan.
28. Reassemble transmission by reversing steps 3 through 25.
29. Install torque converter and hold in place with torque converter retaining bracket from replacement transmission.
30. Return any loose items by attaching to bellhousing in plastic bag.
NOTE:
All parts must be returned with transmission.