Remove and Install

Removing and Installing





1 Disconnect negative cable from battery.
2 Disconnect longitudinal engine throttle control shaft.





3 Unhook control pressure cable (98).

In vehicles with engines 116 and 117, pull out circlip (20) and control cable





In vehicles with engines 103 and 104, compress both lugs on the plastic clip (18) with pliers and pull out the cable in the direction of the arrow

Installation Note
Adjust control pressure cable.





4 Unscrew transverse yoke center assembly (4).





5 Remove/install connecting member (5), model 124.036.





6 Unscrew drain plugs (1 and 2) and drain oil.

Installation Note
Tightening torque:
Oil pan 14 Nm
Converter 16 Nm.








7 Unscrew bolts (17) for driver plate of torque converter (total of 6 bolts).

Installation Note
Tightening torque 42 Nm.





8 Insert a suitable wooden wedge (arrow) between engine oil pan and transverse yoke.
9 Remove entire exhaust system assembly.





10 Remove cross member (22) with rear engine mount.





11 Release cable strap (23) and unscrew cable (6) on kickdown solenoid valve (61). Unscrew retaining bolts for pulse generator (arrow) and pull out pulse generator.

NOTE: On vehicles with mechanical speedometer, disconnect shaft. On vehicles with catalytic converter heating, disconnect cable from shift point retard.






12 In vehicles with 8-cylinder engines, disconnect plug for upshift delay cable (X22/7).





13 slacken propeller shaft clamping nut (7).

Installation Note
Tightening torque 30-40 Nm.





14 Unscrew propeller disc at transmission.
15 Remove plug for starter lockout switch (8). The plug is secured by a locking device. The locking device must be turned upwards (arrow) before the plug can be disconnected.
16 Unhook shift rod from range selector lever.
17 Disconnect vacuum shift rod fir vacuum box (white), mode program (red) and shift point retard (black/green).





18 Unscrew oil cooler feed and return lines (12 and 13).

Installation Note
Replace sealing rings





19 Unscrew bolt (14) and bracket on cylinder head for oil filler pipe (15) and push pipe upwards.
20 Unscrew all hexagon bolts holding the transmission, apart from the two bolts at the side.

NOTE: In 8-cylinder engines, two hexagon bolts (27) are replaced by stay pins with hexagon nuts.





21 Raise transmisssion using attachment 140 589 02 62 00 (60) for vehicle lift.
22 Unscrew side bolts, push transmission towards the rear and lower carefully.

Installation Note
Observe correct seating of plain dowel pins. Raise transmission and push forwards at the height of the engine until the converter housing rests snugly.





23 Rotate plastic retaining pin (arrow) for torque converter in a counter-clockwise direction through 1/4 revolution using an 8 mm Allen wrench and remove. Bolt handles (065) to torque converter and lift out torque converter.





24 Checking installed height of torque converter in transmission housing

Using a depth gauge, measure the distance "A" between the transmission housing and converter fixing.

Engine Distance
104 9.6mm
119 29.8 mm
120 21.6 mm
All diesel engines 8.7 mm

If the torque converter is not correctly seated in the transmission housing, this causes irreparable damage to the torque converter and the primary pump.








25 Checking torque converter. Excessive engine speeds which cause overspeed damage to the engine, can also result in permanent widening of the torque converter. This then fouls the primary pump and damages the radial seal ring.

The overall height of the torque converter must therefore he measured each time the engine is damaged due to overspeed.

26 Place the torque converter on a measuring plate with the primary pump flange downwards and measure dimension "A". If dimension "A" is less than 121.5 mm, the torque converter can be reused; it the measured value is greater, the torque converter should be replaced.

NOTE: If it is necessary to replace the torque converter, the primary pump radial seal ring is also to he replaced.





27 Flushing out torque converter. If the transmission oil is burnt, interspersed with lining abrasion and/or metal swarf, the torque converter, oil cooler lines and oil cooler must be flushed out.

28 Fill torque converter hall full with ATF oil. Insert flushing mandrel (63) and drive at low speed for approx. 2 minutes using a hand drill. Then drain ATF oil through a clean cloth via the drain plug and allow the oil to drip through.

If after this there is metal swarf in the cloth, the torque converter must be replaced.





29 Screw oil cooler with oil cooler lines (49) onto the injector (064) and flush out with ATF oil ensuring that the transmission oil flows freely. Then blow out oil cooler with oil cooler lines with compressed air.