Vehicles With 4MATIC

Removal and Installation of Transmission With Torque Converter





Battery grounding line
Disconnect and connect.
Damping mat of unit compartment wall
Protect against damage by means of a suitable sheet metal cover.
Hydraulic system
Make pressureless by throwing service valve. Vent according to repair instructions.
Holder (28)
Screw off and on at cylinder head.
Pulling wire control pressure (98)
Force off ball socket (19), pull out lock, if required, pulling wire disengage and engage, and adjust.
Exhaust system (100)
Completely remove and install, remove exhaust side support (24).
Shielding plates (3)
Remove and install (item 8).
Oil from transfer case
Drain, filling capacity 0.7 liters (item 9).
Oil from transmission and torque converter
Let oil run out, drain plugs (1 and 2) 14 Nm, fill in correct oil quantity, correct with engine at operating temperature. Filling-in funnel 126 589 12 63 00
Pressure oil line of AV and ZS coupling
Remove and install, close openings with blind plugs, check lines for leaks.
Transmission (1) with transfer case
Support;mount 124 589 00 62 00 (item 13)
Cross bridge (31)
Remove and install (item 14)
Propeller shaft (7)
Loosen and fasten clamping nut (200), 30-40 Nm; torque wrench 001 589 66 21 00 open end wrench 126 589 00 01 00. Unscrew hex. head bolts (25). Loosen fitted sleeves in three-legged flange, renew hex. nuts (26).
Engine carrier rear (22)
Screw off and on at frame floor and engine mount, hex. head bolts and washers (23c) 40 Nm, hex. head bolts (23b) 20 Nm.
Propeller shaft front (40)
Loosen and fasten clamping nut 30-40 Nm.
Torque wrench 001 589 66 21 00.
Open end wrench 201 589 00 01 00.
Hex. head bolts (44)
Remove and install, loosen fitted sleeves in three-legged flange, renew hex. nuts (43).
Hex. socket screws (41)
Remove and install, renew, 25 Nm. Flange wrench 117 589 01 07 00, remove three-legged flange.
Hex. bolts driven plate-torque converter (17)
Screw off and on (6 each) 42 Nm, unscrew pertinent cover plate or supporting shell.
Cable kickdown solenoid valve (6) and impulse transmitter or speedometer shaft (5)
Screw off and on.
Plug for starter locking switch (8)
Force off and on, turning respective lock in upward direction.
Shift rod (9)
On range selector lever, disengage and engage.
Vacuum line (10)
Pull off, plug on (item 27).
Oil cooler forward and return line (12, 13)
Remove and mount, renew sealing rings.
Oil filler pipe (15)
Slip out and in, loosen hex. head screw (14) for this purpose.
Transmission (1)
Lift with mount 124 589 00 62 00, screw all hex. head bolts (21) off and on; M 10 = 55 Nm, M 12 = 65 Nm. Slip transmission with torque converter horizontally out and in.

Special Tools:

NOTE: Below is a description for removing and installing the transmission of model 124.230. For models 124.2261 290/330/393 the assembly is essentially the same, and procedure can be in accordance with these instructions. Vent upon installation of hydraulic system.

Removal and installation

1 Disconnect grounding cable on battery.
2 To prevent damage to damping mat of unit compartment well when lowering transmission, protect damping mat with a suitable sheet metal cover.
3 Make hydraulic system pressureless by throwing lever on service valve (test position).

Installation Note





Lever on service valve in operating position.

4 Unscrew holder for oil filler pipe on cylinder head.





5 Force off ball socket (19).
6 Compress both links on plastic clips (18) with pliers and pull out wire rope in direction of arrow.

Installation Note
Adjust wire rope for control pressure.





7 Completely remove exhaust system (100) with lateral support (24).
8 Remove shielding plates (3).





9 Drain oil from transfer case (arrow).

Installation Note
Filling capacity 0.7 1.





10 Unscrew drain plug on oil pan and let oil run out.
11 Unscrew drain plug on torque converter (2) and let oil run out.

Installation Note
Screw in drain plug on oil pan and on torque converter and tighten to 14 Nm.





12 Unscrew pressure oil line for AV and ZS coupling on transfer case.

Installation Note
Check pressure oil lines for leaks.





13 Unscrew two screws on transmission. Lift transmission and transfer case with pit lift mount.
Mount 124 589 00 62 00

Caution!
Joint should be rotatable in driving direction.





14 Unscrew cross bridge (31) on center tunnel.
15 Unscrew propeller shaft on gearbox flange. Companion plate remains on propeller shaft. Loosen vulcanized centering sleeve in gearbox flange with a mandrel of 10 mm dia.





16 Loosen clamping nut (SW41) of propeller shaft. Slide propeller shaft back as far as possible.

Installation Note
Tighten clamping nut of propeller shaft to a tightening torque of 30-40 Nm.

Special tools
Torque wrench 001 589 66 21 00
Open end wrench 126 589 00 01 00





17 Unscrew engine carrier (22) at the rear on frame floor.

Installation Note
Hex. head bolts on rubber mount (23b) 20 Nm
Hex. head bolts on frame floor (23a) 40 Nm





18 Loosen clamping nut of propeller shaft, front axle.

Installation Note
Tighten clamping nut to a tightening torque of 30-40 Nm.
Open end wrench 201 589 00 01 00
Torque wrench 001 589 66 21 00





19 Unscrew propeller shaft front axle on transfer case in such a manner that the companion plate remains on propeller shaft. Prior to pushing back companion plate from three-legged flange loosen fitted sleeves in three-legged flange. For this purpose, use a cylindrical mandrel of 10 mm dia. and approx. 150 mm in length.





20 Unscrew propeller shaft toward front axle from front axle housing. For this purpose, apply counter- hold at connecting flange by means of a 65 mm open end wrench and unscrew 6 screws M 8x20 (micro. encapsulated). Make sure that the connecting flange is not pushed out of gears.

Installation Note
Renew self-locking hex. socket screws. Tightening torque 20-25 Nm.
Flangewrench 117 589 01 07 00.





21 Unscrew cover plate (16).





22 Unscrew screws (17) drive plate - torque converter (a total of 6 each).

Installation Note
Tightening torque 42 Nm.





23 Remove plug for starter lockout switch (8).

Caution
Plug for starter lockout switch is secured by a lock (white plastic ring); turn this ring in upward direction and carefully force off by means of two screw drivers at cable outlet and at link.

24 Unscrew cable (6) from kickdown-solenoid valve.
25 Remove impulse transmitter or mechanical speedometer drive.





26 Disengage shift rod (9) in range selector lever (52).





27 Unscrew holder (26) and pull off vacuum line (10).





28 Disconnect oil cooler feed line (12) and oil cooler return line (13).

Installation Note
Renew sealing rings for forward and return line.

29 Unscrew fastening screw (14) for oil filler pipe (15) and slide oil filler pipe in upward direction.





30 Unscrew all screws for fastening transmission to intermediate flange.

Installation Note
Tightening torque 1110 55 Nm
1112 65 Nm

31 Pull transmission with transfer case horizontally to the rear (arrow). Then carefully lower transmission.

Installation Note
Lift transmission and slide at engine level in forward direction until converter housing rests well against engine.

32 Check torque converter and clean, if required, install.
33 Fill up with transmission fluid through filling funnel with filter 126 589 12 63 00 and check oil level. With transmission at operating temperature and correct fluid level, the readout should be at max. mark.