To 09/89

Removing and Installing Transmission with Torque Converter







Negative cable at battery
Disconnect, connect.

Bracket (28)
Unscrew at cylinder head, screw on.

Control pressure cable (98)
Press off ball socket, withdraw locking element (20), if necessary, detach, attach cable (steps 3 - 8). Adjust cable for control pressure.

Engine compartment panelling (30)
Unscrew, screw on.

Oil from transmission and torque converter
Drain, pour in oil after repair, check and adjust to correct level.
funnel 126 589 12 63 00
drain plugs (2) and (3) 14 Nm.

Bolts of torque converter driven member plate (17)
Unscrew, screw in (6 off), 42 Nm.

Crossbar (22)
Remove with rear engine mount, install.

Exhaust support (24), flexible coupling (25)
At transmission joint flange, unscrew, screw on.

Exhaust system
Detach at rear hanger, attach.

Propeller shaft clamping nut (7)
Slacken and push propeller shaft together as tar as possible. Tightening torque 30 Nm. torque wrench 001 589 66 21 00 open-end wrench 46 mm 126 589 00 01 00 or 201 589 00 01 00.

Cable of kickdown solenoid valve (6) and pulse generator or speedometer shaft (23)
Detach, attach.

Shift rod (9)
Detach at range selector lever. attach.

Plug for starter lockout switch (8)
Press off, on, turn lock up the way for this step.

Vacuum line (10)
Detach and fit on.

Oil filler pipe (15)
Push out, push in, slacken bolt (14) for this step.

Supply and return line of oil cooler (12, 13)
Detach, attach, renew seals.

Transmission (1)
Raise with adapter 116 589 06 62 00, unscrew all bolts (21), screw in, M10 = 55 Nm.
Pull Out transmission with torque converter horizontally, push in (steps 27 - 32).

Torque converter
Withdraw, insert, take out plastic retaining pin for this step and install handles 126 589 01 62 00.
Pay attention to installation instructions steps 31 and 35.

Oil cooler with oil cooler line and torque converter
Rinse with petroleum it transmission oil is scorched or contaminated with lining abrasion.
Rinsing mandrel 116 589 00 15 00,
Hand pump 112 589 00 72 00.
If metal swarf is present in oil, torque converter must be renewed (steps 36 - 38).


Special tools







Removal and Installation






Attention:
To avoid damaging the component compartment panel, a 300 x 300 mm metal sheet must be inserted as a protection for the insulation matting on the component compartment wall when performing any work which involves lowering the transmission at the rear. Detach exhaust system at the rear hanger and secure approx. 50 cm lower with a wire.






Attention:
On vehicles fitted with auxiliary heater, ensure that the water hose (arrow) is not damaged when lowering the transmission.

Detach accelerator control Model 123.






1. Disconnect negative cable of battery.

2. Unscrew bracket (28) for the oil filler pipe at cylinder head and bracket at the valve hood.






Vehicles with Injection engines

3. Press off ball socket (19).

4. Detach control pressure cable (98). Withdraw locking element (20) and slacken cable.






5. Use a screwdriver to press the plastic ball socket apart (arrow) and pull off retaining bar at the fulcrum lever.

Models with carburetor engine

6. Press off ball socket (19). Compress retaining clip (arrow) and detach cable for control pressure (98).






Models 123 and 126 with diesel engine

7. Press off ball socket (19), compress plastic clip with pliers and remove control pressure cable (98).






Models 201 and 124 with diesel engine

8. Press oft ball socket (19), remove retaining clip and detach control pressure cable (98).






Installation Instruction

Adjust cable for control pressure.



9. Unscrew engine compartment panelling at bottom.






10. Unscrew drain plug at oil sump (4a) and also at torque converter (2) and allow oil to drain out.

Installation Instruction
Tightening torque 14 Nm.

11. Unscrew bolts (17) of torque converter driven member plate (total of 6 bolts)


Installation Instruction
Tightening torque 42 Nm.






12. Remove crossbar (22) with rear engine mount.

13. Unscrew exhaust support (24). Unscrew flexible coupling (25) from transmission joint flange.

Note:
Slacken the flexible coupling installed at the transmission end with a drift.






14. Detach exhaust system at the rear hanger:






15. Unscrew exhaust shield.






16. Slacken propeller shaft clamping nut (7) and push the propeller shaft together as far as possible

Torque wrench 001 589 66 21 00,
open-end wrench 46 mm 126 589 00 01 00 or 201 589 00 01 00.






Installation Instruction
Tightening torque 30 Nm






17. Detach cable (6) at the kickdown solenoid valve.

18. Slacken speedometer shaft (23). On vehicles fitted with electronic speedometer. unscrew pulse generator.

19. Detach shift rod (9) at the range selector lever.

20. Take off fastening clip for speedometer shaft.

Installation Instruction
Ensure proper routing.






21. Turn locking bar (arrow) out to the road up the way and detach plug from starter interlock switch (53).

22. Detach vacuum line at the vacuum unit.

23. Detach vacuum line of vehicles with selector programme at the vacuum element (control pressure cable).

24. Detach cable on vehicles with shift point retard from switchover valve.


Installation Instruction
Ensure proper routing.






25. Unscrew hexagon socket bolt (14) and withdraw oil filler pipe (15) up the way.






26. Unscrew oil cooler lines (12. 13) and fastening clips (arrows).

Installation Instruction
Renew sealing rings for supply and return lines.

27. Unscrew all the transmission-engine bolts with exception of the two bolts (21) on left and right.






28. On vehicles fitted with engine 601 and 602, insert the retaining device for the torque converter (080) 201 589 00 40 00 into the ventilation grille Cutout and screw in the stut bolt (081) far enough for it to engage in the hexagon socket of the oil drain plug.






29. Slightly raise transmission with adapter 116 589 06 62 00 for inspection pit lift (060).

30. Unscrew the side bolts (21).

31. Push transmission back - as far as the propeller shaft permits - and carefully lower.

Installation Instruction
Raise transmission and push forward at engine height until torque converter housing is resting snugly against the engine. Connect grounding strap (36).

32. Lift transmission off the removal and installation device.






Installation Instruction
Turn torque converter so that one of the three threaded plates is exactly at the bottom.

Apply a light coating of grease to the centering spigot on the torque converter.






33. Position transmission vertically.

34. Turn plastic retaining pin (arrow) for the torque converter 1/4 turns counter-clockwise with 8 mm hexagon socket wrench, and remove.

35. Screw handle (065) 126 589 01 62 00 onto the torque converter.

36. Withdraw torque converter.

Attention:
If the transmission oil smells scorched or is contaminated with lining abrasion, torque converter, oil cooler lines and oil cooler must be rinsed.

It metal swarf is present in the transmission oil sump, the torque converter must be renewed. Metal swarf is not completely removed by rinsing and may cause subsequent transmission damage.

Installation Instruction
Grease drive flange (32) with Molykote.






When inserting torque converter, turn back and forward to ensure that the teeth mesh properly.
Insert plastic retaining pin and turn l/4 turns clockwise.






37. Rinse torque converter by pouring in 1 litre of petroleum. Insert rinsing mandrel (063) 201 689 05 15 00 and drive at a low speed for approx. 2 minutes with a hand power drill. Then allow petroleum to flow off through the drain plug.

Repeat rinsing operation 2 - 4 times until the petroleum flowing out is clean.






38. Screw oil cooler with oil cooler lines (12) and (13) to the syringe (064) 112 589 00 72 00, rinse out with cleaning agent and blow dry thoroughly.

39. Pour in transmission oil and check oil level.