Part 1
Control pressure cable (98)
Slacken, remove and attach locking device with screwdriver (item 1)
Transmission (1)
Clamp on assembly trestle 116 589 06 59 00 and mounting plate 126 589 10 63 00 (item 2).
Oil pan (3)
Remove, install, Hexagon bolts 8 Nm (item 3).
Oil fitter (5)
Remove, install, Cross-head bolts 4 Nm (item 4).
Shift valve housing (A)
Remove, install, 8 Nm, note different length of bolts (item 5).
Leaf spring (142) and bracket (141)
Remove and install with hexagon bolt (140), 8 Nm (item 6).
Lower cover (13) with intermediate plate (14) and oil pipe (9)
Remove, install. Bolts with washers (8), 8 Nm. Raise complete unit and dismantle lower cover. Check clearance between shut-off plunger and stop for spring linkage (0.4 - 1.0 mm) (item 7).
One-way valve (49), brake band guide B2 (101), locating pin (135), oil deflector (119), temperature throttle (117)
Remove, install (item 8).
Filer piece (128)
If fitted, check that it is secure.
Brake band plunger cover B2 (17)
Remove by extracting circlip (23) (item 9).
Brake band plunger B2 (15)
Remove, install. When installing. adjust clearance "L" with thrust pin (26) 5.5-6 mm (item 127).
Brake band plunger B1 (37)
Remove and install with assembly device 201 589 03 59 00. Remove circlip (41), cover (40) and return springs (35, 36). When installing, adjust clearance "L" to 1.8 - 2.4 mm as described in items 118 to 124. Check measuring device 126 589 00 21 00, lip sealing ring (39) (items 12 - 15).
Brake band guide B1 (34)
Remove, install (item 16).
Thrust element of thrust bearing B1 (31)
Remove, install; unscrew, screw on screw plug (33) or transmission overload protection switch (330), 70 Nm. Replace O-rings (32) (item 17).
Range selector lever (52)
Pull off by unscrewing hexagon bolt (51), 8 Nm (item 19),
Starter lockout switch (53)
Remove by unscrewing bolts (55), 8 Nm. Locate when installing (see item 20).
Vacuum unit (60)
Remove and install with retaining plate, 8 Nm. Remove and insert modulating pressure control valve (59) and heat expansion pin (59a) (items 21, 22).
Kickdown solenoid valve (61)
Unscrew, screw on, 20 Nm (items 23, 111).
Joint flange (64), or internally-geared wheel (64a)
Remove, install. Slacken twelve-point collared nut (62 or 120 Nm, lock (items 24, 110). Wrench socket 126 589 02 09 00.
Washer (65)
Remove (item 25).
Rear transmission cover (70) or adapter housing (70a)
Unscrew, screw on hexagon bolts (71), 13 Nm (8.8). or 28 Nm (12.9). Then remove cover by tapping gently with a hammer and dismantle. Check seal (items 26, 27, 107).
With electronic speedometer, parking lock gear (73) with rotor, parking lock paw (74) and spring (75)
Remove install (items 29, 103, 104).
Oil pipe (102) for mechanical speedometer drive
Disconnect, connect (item 30).
Parking lock gear (73), parking lock pawl (74) and spring (75)
Remove, install (items 30. 103. 104).
Shim (77)
Determine thickness by measuring axial play of output shaft (item 105).
Attachment - 126 589 04 31 00
Measuring sleeve - 126 589 06 14 00
Plastic guide (80) and roller (81)
Pull off, push on (items 31, 100 and 101).
Spring linkage with notched plate (82)
Unscrew, screw in hexagon socket bolt (82a). then pull out shaft (76) and remove notched plate (item 32).
Oil pipe (84)
Remove, install. 8 Nm (items 33. 97).
Secondary pump (20)
Remove, install. Nut (44) 6 Nm, allen bolts (45) 8 Nm, (items 35 96). Remove O-ring (22) and intermediate plate (21) (items 36 94).
Centrifugal governor (50)
Pull out after removing circlip (47) and cover (46), insert. To do this, the axial retainer (43) must be swivelled back (items 37 - 38, 90 - 92).
Axial retainer (43), helical gear (78) and snap ring (116)
Remove, install (items 39 - 41, 88, 89).
Front transmission cover (10)
Remove, install complete. Bolts with washers (18) 13 Nm, dismantle, note location of teflon rings. Before installation, measure axial dearance "B" for dutch K1 and adjust. 0.4-0.6 mm (see item 83). Then insert shim (95), friction ring (96) and axial bearing into dutch K1.
Gear set (69)
Remove complete. When installing, adjust clearance "L" = 1.5-2.0 mm of multiple-disc clutch B3 (item 76). Insert discs (133) and belleville spring (85) (item 44).
Brake band B1 (30) and dutch K1
Remove and install with gear set (see items 45, 78).
Damping spring (134)
Remove, install (item 47, 74).
Thrust pin (28)
Remove, install (item 48, 125).
Clutch K2 (100)
Pull out, when installing, push onto gear set and push in with gear set (items 49, 69).
Brake band 132 (27)
Remove, install by compressing brake band as much as possible (68) (items 50, 68).
Support disc (113)
Remove, install (item 66).
Thrust element B2 (29)
Pull out, check and insert with tab upwards (items 51, 64).
Support flange (79)
Remove, install. Bolts (114) 11 Nm. Stick teflon rings (115) into groove with grease (items 54, 60 - 62).
Guide ring (88a) and lip sealing ring (88)
Check and replace if necessary. Drift is shop-made tool (item 56).
O-rings (91, 92), sealing rings (92) and aluminium sealing rings (90)
Check and replace if necessary (items 57 - 59).
Special Tools:
Adjustment Data
Adjustment Data:
Dimensions
Dimensions:
Disk Versions:
NOTE: During assembly, particular care must be taken when handling the sealing surface of the oil distributor plate cast in the transmission housing. The utmost cleanliness must also be ensured. The transmission will only function properly if there is no dirt on the transmission components or in the oil circuit. For this reason, always remove sealant residues after dismantling, wash all parts carefully, flush out oil channels and blow clean with compressed air.
Rubber seals must not be permitted to come into contact with benzine, which may attack the rubber. Use alcohol to clean rubber parts. Also ensure that the parts do not come into contact with woolen cloths, as any fuzz adhering to the parts may result in malfunctions.
In vehicles with 4MATIC, the adapter housing with internal gear is fitted in place of the rear transmission cover and 3-arm flange. The repair procedure is largely identical for both versions.
Assembling
NOTE: When assembling, coat bearings and sliding surfaces with the specified ATF. Before installing, immerse new brake bands and lining discs of multiple-discs brake in ATF for approx. 1 hour.
NOTE Steps 1 - 54 are part of the dismantling procedure. Dismantling
55. Place housing (1) into assembly device and secure in place with the bolt (arrow).
56. Insert plastic guide ring (88a) for plunger B2, then insert lip sealing ring (88) using the shop-made drift. The sealing lip (arrow) must point in the direction of the brake band plunger cover.
NOTE: The impact drift must be manufactured in accordance with the specified dimensions.
57. Place O-ring (91) in groove.
58. Insert radial sealing ring (92).
59. Screw in screw plug (90) with new aluminium sealing ring and tighten to 10 Nm.
60. Place O-ring (arrow) in groove.
61. Coat grooves in support flange K2 (79) with grease. Insert teflon rings (115) and push into the groove so that the diagonal cut (arrow) remains closed.
62. Insert Support flange (79) following the pattern of holes for the retaining bores; use two bolts, approx. 80 mm long. for centering.
63. Screw in combined bolts and washers (114) and tighten to 11 Nm.
64. Check thrust element B2 for twisting. With the thrust element removed, the bore and tab (arrows) must align. With the thrust element installed, one spring winding of the thrust element must be visible through the bore for the lower cover oil pipe.
65. Insert thrust element B2 (29) with the tab (arrow) upwards.
NOTE: Use of pressure element B2 (29) with increased spring force.
Vehicles with M 117/119 - as of transmission no. 3 305 965
Other vehicles - as of transmission no. 3 307 060
66. Insert support ring (113) in such a way that the lug for the anti-rotation element (arrow) is located in the housing.
NOTE: As of 08/94, an axial bearing is installed instead of the support ring (113).
67. Recheck seating of teflon rings on support flange (79).
68. Compress brake band B2 (27) at the support lugs as far as possible and insert in housing. To facilitate assembly, the brake band may be heel together with the aid of the locking device (23).
NOTE: As of 10/89, use of brake band B2 (27) with Raybestos coating for improved shifting quality.
69. Attach clutch K2 (100) onto gear set.
70. Insert gear set in transmission housing whilst rotating drive shaft (87).
71. Position transmission vertically with drive shaft (87) uppermost.
72. Check installed position of gear set. The gear set is correctly installed when the top edge of the connecting member (arrow) is lower than the bearing surface (138) of the outer multiple-disc LB3.
73. Assemble front cover with primary pump.
74. Insert damping spring (134).
NOTE: As of transmission no. 3 716 425 an additional plastic washer is fined.
75. Assemble discs for multiple-disc brake LB3 in the sequence illustrated in the figure and insert individually.
NOTE: As of transmission no. 3 991 611, use of disk spring (85) with increased stroke.
76. Measure clearance "L" of multiple-disc brake LB3 and compensate.
Measuring distance "a"
Place parallel-edged block (029) on the machined surface and measure depth to outside edge of spring seat (85) using a depth gauge.
Determining distance "b"
Place parallel-edged block (029) on plunger of multiple-disc brake (arrows) and measure depth to gasket (11) using a depth gauge. The clearance "L" is the difference between the two measurement. Adjust dearance "L" to its specified value of 1.5 - 2.0 mm. Variations can be compensated by means of the outer multiple-discs available in different thicknesses (133a illustration item 75).
77. Coat groove in driveshaft (87) with grease. Insert lubricating pressure ring (99) and push into groove so that the gap remains closed.
78. Engage assembly lock (arrow) on brake band B1 (30).
79. Insert clutch K1 (83) while rotating so that the splines engage.
80. Insert brake band B1 (30) 50 that the pin of the assembly lock (arrow, figure to item 78) points towards thrust element B1.
81. Replace O-rings. Then insert thrust element B1 (31) with pressure pin and screw in screw plug (33) or overload protection switch (33b) and tighten to 70 Nm.
82. Insert brake band guide (34) ensuring that the locating pins engage in the bores in the housing and press it in until it locks in position detectably.
83. Measure axial play "B" for clutch K1 and correct. Axial play "B": 0.6 - 1.0 mm. Position seal (19) on front cover (10).
Place parallel-edged block (029) on flange (arrow).
Measure from parallel-edged block to gasket (11) using depth gauge (distance "b").
Place parallel-edged block (029) on machined surface of transmission housing. Measure from parallel-edged block to contact surface in clutch K1 (83) using depth gauge (distance "a").
Hold shim (95), thrust washer (96) and axial bearing (97) together and measure distance "C" using caliper gauge.
Distances "b" and "c" subtracted from distance "a" equal the axial play "B" of clutch K1. The axial play can be adjusted by inserting appropriate shims (95, thickness 0.1, 0.2, 0.5 mm).
84. Insert measured shims, friction ring and axial bearing one by one into clutch K1 (see figure item 83).
Note: Procedure continues in Part 2. Part 2