Up to 5/91

NOTE: The following description applies for the removal and installation of the transmisson for model 124.230. The procedure for models 124.226/290/330/393 is largely identical and thus these instructions can be followed for these models. Bleed hydraulic system after installation.

Removing and Installing





1 Disconnect ground cable from battery.
2 In order to avoid damaging the insulating mat of the component compartment bulkhead when lowering the transmission, cover the insulating mat with a suitable metal sheet.





A Test position
B Operation position

3 Release pressure from hydraulic system (test position). As of 05/91 also release reservoir pressure at drain plug of valve control unit.





4 Unhook control pressure cable (98).

Installation Note
Adjust control pressure cable.

5 Remove entire exhaust system complete with side support.
6 Drain oil from transfer case. Replace sealing rings.
7 Drain oil from torque converter and transmission oil pan. Tightening torque 14 Nm; torque converter 16 Nm.





8 Unscrew pneumatic oil line for axle distributor and central lock connector (AV and ZS) at transfer case. Seal openings with blind plugs.

Installation Note
Check pneumatic oil lines for leaks.





9 Unscrew two bolts on transmission. Raise transmission and transfer case with vehicle lift attachment. Jointed element must be rotatable in direction of travel
10 Unscrew cross piece in transmission tunnel.
11 Unscrew propeller shaft at transmission flange. Propeller disc remains on propeller shaft.

Installation Note
Replace hexagon nuts.

12 Slacken propeller shaft clamping nut. Push propeller shaft back as far as possible.





Installation Note
Tightening torque 30-40 Nm.

13 Unscrew rear engine support (22) at floor frame.

Installation Note
Hexagon bolts on engine mount (23b), tightening torque 20 Nm.
Hexagon bolts on floor frame (23a), tightening torque 40 Nm.





14 Slacken clamping nut at front of propeller shaft and unscrew so that propeller disc remains on the shaft.

Installation Note
Tightening torque 30-40 Nm.

15 Unscrew propeller shaft to front axle at front axle housing. To do this, steady the connecting flange with a 65 mm open-end wrench and unscrew 6 M8x20 bolts. Ensure that the connecting flange is not pushed out of the splines. Remove propeller shaft.

Installation Note
Tightening torque 20-25 Nm.





16 Unscrew cover plate on torque converter bolts.
17 Unscrew hexagon bolts (17) for torque converter driver plate (total of 6 bolts).

Installation Note
Tightening torque 42 Nm.





18 Remove plug for starter lockout switch (8).

Caution:
The plug for the starter lockout switch is secured by means of a locking device (white plastic ring); turn this upwards and press off carefully using two screwdrivers at the outgoing cable and at the lug.

19 Unscrew cable from kickdown solenoid valve.
20 Remove mechanical speedometer drive shaft.
21 Unhook shift rod.
22 Disconnect vacuum line at vacuum cell.
23 Disconnect and seal off oil cooler feed and return lines (13), replace sealing rings.





24 Unscrew retaining bolt (14) and bracket on cylinder head for oil filler pipe (15) and push filler pipe upwards.
25 Unscrew all bolts holding transmission to intermediate flange.

Installation Note
Tightening torques: M10=55 Nm, M12=65 Nm





26 Raise transmission with attachment and pull horizontally backwards (arrow) together with transfer case. Then lower transmission carefully.

Installation Note
Raise transmission and push forwards at the height of the engine until the converter housing rests snugly against the engine. Attachment 124 589 00 62 00.





27 Checking installed height of torque convener in transmission housing
Using a depth gauge, measure the distance "A" between the transmission housing and converter fixing.

Engine Distance
103 9.6 mm
603 8.7 mm

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





28 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 be measured each time the engine is damaged due to overspeed.

29 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; if 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 be replaced.





30 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.





31 Fill torque convener half 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.





32 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.