Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 438

(a) Attach Adapter 8266-18 (2) to Handle 8266-8

(1).

(b) Attach dial indicator C-3339 (3) to Handle

8266-8 (1).

(c) Install the assembled tool onto the input

shaft of the transmission and tighten the retaining
screw on Adapter 8266-18 (2) to secure it to the
input shaft.

(d) Position the dial indicator plunger against a

flat spot on the oil pump and zero the dial indica-
tor.

(e) Move the input shaft in and out. Record the

maximum travel for assembly reference.

(4) Loosen guide bushing (12) (Fig. 40) and remove

from transmission housing.

(5) Detach oil pan (5) (Fig. 40).
(6) Remove oil filter (4) (Fig. 40).
(7) Unscrew Torx socket bolts (3) and remove elec-

trohydraulic unit (2).

(8) Place the transmission in PARK to prepare for

the removal of the output shaft nut.

(9) Remove the nut holding the propeller shaft

flange to the output shaft and remove the flange.

(10) Remove the transmission rear oil seal with a

suitable slide hammer and screw.

(11) Remove the transmission output shaft washer.

Be sure to tag the washer since it is very similar to
the geartrain end-play shim and they must not be
interchanged.

(12) Remove the transmission rear output shaft

bearing retaining ring (1) (Fig. 41).

Fig. 40 Remove Electrohydraulic Unit

1 - HEAT SHIELD
2 - ELECTROHYDRAULIC UNIT
3 - BOLT
4 - OIL FILTER
5 - OIL PAN
6 - CLAMPING ELEMENT
7 - BOLT
8 - DRAIN PLUG
9 - DRAIN PLUG GASKET
10 - 13-PIN PLUG CONNECTOR
11 - BOLT
12 - GUIDE BUSHING

Fig. 41 Remove Rear Output Shaft Retaining Ring

1 - RETAINING RING
2 - OUTPUT SHAFT BEARING

Fig. 42 Position Remover 9082 On Bearing

1 - BEARING REMOVER 9082
2 - TRANSMISSION CASE
3 - OUTPUT SHAFT BEARING

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(13) Position Bearing Remover 9082 (1) (Fig. 42)

over the inner race of the output shaft bearing (3).

(14) Slide the collar (3) (Fig. 43) on the Bearing

Remover 9082 (1) downward over the fingers (4) of
the tool.

(15) Remove the output shaft bearing (3) (Fig. 44).
(16) Remove the geartrain end-play shim from the

output shaft. Be sure to tag the shim since it is very
similar to the output shaft washer and they must not
be interchanged.

Fig. 43 Slide Remover 9082 Collar Downward

1 - BEARING REMOVER 9082
2 - TRANSMISSION CASE
3 - COLLAR
4 - FINGERS

Fig. 44 Remove Output Shaft Bearing

1 - BEARING REMOVER 9082
2 - TRANSMISSION CASE
3 - OUTPUT SHAFT BEARING

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(17) Remove the bolts holding the transmission

housing to the converter housing from inside the con-
verter housing.

(18) Stand the transmission upright on the con-

verter housing. Be sure to use suitable spacers
between the bench surface and the converter housing
since the input shaft protrudes past the front surface
of the housing.

(19) Remove

the

remaining

bolts

holding

the

transmission housing to the converter housing.

(20) Remove the transmission housing from the

converter housing.

(21) Remove output shaft with center and rear

gear set and clutch K3 (3) (Fig. 45).

(22) Remove thrust needle bearing (4) and thrust

washer (5) (Fig. 45).

(23) Remove input shaft with clutch K2 and front

gear set (6).

(24) Remove clutch K1 (1).

Fig. 45 Remove K1, K2, and K3 Clutches

1 - DRIVING CLUTCH K1

5 - THRUST WASHER

2 - SUN GEAR OF FRONT PLANETARY GEAR SET

6 - FRONT PLANETARY GEAR SET, DRIVING CLUTCH K2, AND
INPUT SHAFT

3 - DRIVING CLUTCH K3, OUTPUT SHAFT, AND CENTER AND
REAR PLANETARY GEAR SETS

7 - SEALING RINGS

4 - THRUST NEEDLE BEARING

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(25) Unscrew Torx socket bolts (4) (Fig. 46) and

remove oil pump (6). Screw two opposed bolts into
the oil pump housing and press the oil pump out of
the converter housing by applying light blows with a
plastic hammer.

(26) Remove and discard the torque converter hub

seal and the oil pump outer o-ring seal from the oil
pump.

(27) Unscrew Torx socket bolts (1) (Fig. 46) and

remove multiple-disc holding clutch B1 (5) from con-
verter housing. Screw two opposed bolts into the
multiple-disc holding clutch B1 (5) and separate from
the converter housing by applying light blows with a
plastic hammer.

(28) Detach intermediate plate (3) (Fig. 46) from

converter housing (2).

Fig. 46 Remove Holding Clutch B1 and Oil Pump

1 - BOLTS - M6X32

4 - BOLTS - M8X35

2 - CONVERTER HOUSING

5 - HOLDING CLUTCH B1

3 - INTERMEDIATE PLATE

6 - OIL PUMP

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