Extension Housing: Service and Repair

Remove Or Replacing Transmission Extension Housing (A5S 360R/390R)

Special Tools Required:
^ 00 2 030
^ 00 2 550
^ 00 5 010
^ 23 0 020
^ 24 1 090
^ 24 5 301
^ 24 5 305

Note: After completing work, top up transmission fluid level.

Caution: Use only the approved transmission fluid in this automatic transmission.
Failure to comply with this requirement will result in serious damage to the automatic transmission!

Remove complete exhaust system.





The automatic transmissions in question each have an adhesive label on the extension housing at the rear (see fig.).

To avoid damage to the transmission: position the transmission on the assembly stand for the entire operation (output flange facing upwards).

Remove automatic transmission.





Remove treat shield (1).





Remove heat shield (1).





Support transmission with special tools 00 2 030 / 24 5 301 / 24 5 305.





Release screws.
Tightening torque, all mounting points 21 Nm.

Remove cross-member (1).





Release screws.
Tightening torque, refer to propeller shaft replacement.

Installation:

Replace self-locking nuts.





Grip propeller shaft and release nuts.
Tightening torque, center mount to body 21 Nm.

Bend propeller shaft downwards at center bearing (1).

Detach propeller shaft from transmission output flange and tie back to side on vehicle underbody.


To avoid damage to the automatic transmission: position the transmission on the assembly stand for the entire operation (output flange facing upwards).





Note: The automatic transmissions in question each have an adhesive label on the extension housing at the rear (see fig.).





Version 1 without spring washer:
Grip output flange (1) with special tool 23 0 020.

Release hexagon nut.
Tightening torque, 360/390 trans. with spring washer 30 Nm, with out spring washer 60 Nm.

Detach output flange (1).

Installation:
Replace sealing ring in output flange (1).
Install hexagon nut with screw retaining compound.





Version 2 with spring washer:
Release hexagon nut (1) on output flange (2).


Installation:
Install hexagon nut with screw retaining compound.





Version 2 with spring washer:
Remove spring washer (1).

Installation:
Note installation direction of spring washer (1).

Remove output flange (2).

Installation:
Replace sealing ring in output flange (2).





Withdraw radial seal (1) with special tool 00 5 010.





Release screws on transmission extension housing (1).


Carefully pull off transmission extension housing (1).





Replace gasket between transmission housing (1) and end cover.

Caution: Existing shim (2) remains fitted and is not recalculated.





Caution: If shim is lost:
Calculate new shim.
Calculate measurement between contact face (1) and parking gear (2) with special tool 00 2 550.

Shim Table:

Calculate the new shim with this measurement from the table.





Installation:
Coat sealing lips of new radial seal with automatic transmission fluid.
Drive in radial seal with special tool 24 1 090 until flush.