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Transmission Rebuild, 6.9

Started by TJ 450, 03 January 2009, 07:56 AM

TJ 450

#75
AFAIK, WGB's is a 944.

However, my Grandfather has a 928S in Sydney. I must ask him what transmission it has. It's probably the four speed though.

Tim
1976 450SEL 6.9 1432
1969 300SEL 6.3 1394
2003 ML500

Bandolero

I heard today from an experienced Merc and 6.9 mechanic that the Porsche 928 uses the same ZF auto as the 6.9.
Just the bell housing and torque converter are different.
He also said that the bands and clutches are the same!!
If this is the case, we should be able to pay a LOT less for the parts for our 6.9s.
This mechanic also reseals the levelling valves and the hydro pumps.
He knows how to replace the inner seal on the pump because that is the one that leaks. (Between the alloy housing and the metal housing.)
Russell Bond - (Adelaide, South Australia)
1978 450SEL 6.9 .... #5166 .... 12/78 (Sold.) [url="//www.ezycoat.com.au"]www.ezycoat.com.au[/url]

peterq

The early 928 uses the 3 speed from the 6.9, housed in the 928's transaxle. The later 928s (5.0 engines onwards I think) use another Mercedes 4 speed auto box.

TJ 450

Excellent. I will now have to search for an early 928 three speed transmission for my shafts, or perhaps I shall phone the Porsche dealer and get a quote for new.

Tim
1976 450SEL 6.9 1432
1969 300SEL 6.3 1394
2003 ML500

nathan

Peter,
if the later models use a 4 speed, and the earlier ones had the same 3 speed, does this mean you could just fit the 4 speed as it would fit?

Russel, not meaning to dispute you, but it seems no one (including m100 forum) has ever found someone who can reseal these pumps properly? have you used a product that this fellow has resealed?
nathan
1979 116 6.9 #6436
2018 213 e63
2011 212 e63
2011 463 g55
2007 211 e500 wagen
1995 124 e320 cabriolet
1983 460 300gd
1981 123 280te

Bandolero

Not yet. I'm going to give him an old one I got from the wreckers to see how it goes.
He says he's done about 50 of them with no problems.
He also says that he showed someone at BEA how to do it....we'll see.....
Russell Bond - (Adelaide, South Australia)
1978 450SEL 6.9 .... #5166 .... 12/78 (Sold.) [url="//www.ezycoat.com.au"]www.ezycoat.com.au[/url]

TJ 450

Quote from: nathan on 05 May 2009, 06:54 AM
Peter,
if the later models use a 4 speed, and the earlier ones had the same 3 speed, does this mean you could just fit the 4 speed as it would fit?

If it's anything like the later W126 4-speed, it probably wouldn't fit, as the bellhousing is integrated with the trans casing. It would be cool if it was in the same format as the three speed though.

With the suspension pumps, I read on the M100 forum that they can be resealed, as long as the correct material is used for the seals and the pump itself is not worn out.

Tim
1976 450SEL 6.9 1432
1969 300SEL 6.3 1394
2003 ML500

TJ 450

I have now commenced assembly, although it will be a long and tedious task, particularly seeing as I don't have all the components yet!

Previously, the transmission casing was completely dissassembled. All parts have been bagged or cling-wrapped as required. Clutch packs remain assembled and I will attend to those shortly, to replace seals and clutch discs.

Here, I have installed the thrust bodies with new o-rings. They were all dipped in ATF before insertion, pressed in most of the way, retaining clip inserted and then pressed home ensuring that the clip remained properly seated. All this was done without tools.



I also pressed in the B2 lip seal with a suitable mandrel and Powerade lid to take the impact.



Casing was then wrapped in cling wrap again.



Tim
1976 450SEL 6.9 1432
1969 300SEL 6.3 1394
2003 ML500

TJ 450

I collected the bellhousing today, with new stator shaft installed. It is the early type, so no machining was involved.





I have commenced rebuilding the clutch packs... starting with K1.



Progress has stopped, because I need to work out how to install the piston, as the lip seal needs to be compressed for installation. There is a special tool called for for this procedure, which is an introducing ring.

Tim
1976 450SEL 6.9 1432
1969 300SEL 6.3 1394
2003 ML500

TJ 450

OK, here we go with rebuilding Clutch K1.

Here's the lip seal that required working in with a tool (thin plastic sheeting). The special tool normally required is an insertion sleeve.


... the bore that it needs to be worked into.


...the tool for working the lip into the bore.


...the clutch springs with retainer, in place.


...Compressing the springs with the piston from another trans (very dangerous)!


...Properly seated with retaining clip installed.


...Installing new friction discs after ATF bath.


...Top plate installed.


...Wavy Circlip installed... Done! ;)


Tim


1976 450SEL 6.9 1432
1969 300SEL 6.3 1394
2003 ML500

s class

Well done dude.  I think you get the W116.org award for 'most intrepid repairer'.  You are an inspiration to all of us. 


[color=blue]'76 6.9 Euro[/color], [color=red]'78 6.9 AMG[/color], '80 280SE, [color=brown]'74 350SE[/color], [color=black]'82 500SEL euro full hydro, '83 500SEL euro full hydro [/color], '81 500SL

Big_Richard

I suspect that you could of wrapped the piston in over head transparancy film for installation - like a ring compressor, and using ATF slid it home. Special tools, Bah, i never needed special tools - I think thats how i did it.



koan

All I can say is great work and good that you keep up the pictures - it's easy to forget them in middle of something a git tricky.

koan
Boogity, Boogity, Boogity, Amen!

TJ 450

Thanks guys.

It is very easy to forget pictures. In fact, I forgot to mention that there is a second lip seal for the piston of K1... I'll attempt to find the pic for that.

Yesterday was the day of engine removal, which was done with the assistance of PB and Nathan's engine hoist. It went very smoothly, but I suspect that installation will be difficult!







Tim
1976 450SEL 6.9 1432
1969 300SEL 6.3 1394
2003 ML500

s class

Looks good TJ.  Could you please provide a close-up photo of the sticker on the oil filter housing, and what it's part number is?  (stickers usually have the number printed on)


[color=blue]'76 6.9 Euro[/color], [color=red]'78 6.9 AMG[/color], '80 280SE, [color=brown]'74 350SE[/color], [color=black]'82 500SEL euro full hydro, '83 500SEL euro full hydro [/color], '81 500SL