Re: Transmission Arrival & Unboxing
Well, tonight began a big push into the weekend, to make some progress and get my wife's wagon back on the road. It will be three weeks ago on Sunday that the transmission died.
Thought I'd get the jump by getting the rear main seal replaced. Total time out in the shop tonight was about three hours. The main seal took me a bit longer than expected, but I took extra time to ensure that the sealing surfaces at the back of the block were extra clean and oil-free before I mounted up the seal.
Here is how things progressed out in the shop tonight:
The first step was to loosen and remove the flywheel from the end of the crankshaft. This is held on by eight 12-point bolts, which are fastened at a moderate torque. I was able to stop the crank from rotating and then loosened and removed each of the eight bolts, then the mounting plate and then the flywheel itself.
After removing the flywheel, I had the available view to take a close look at the crankshaft seal. It appeared to be oil-tight, with only a little bit of oil blowby and no real oil wetness (indicating fresh oil). Nevertheless, since it was exposed, it was a no-brainer to replace it because it requires transmission removal to do. Here are a couple of views of the crank seal with the flywheel off. Remember, this engine has 203,000 miles on it. From everything I could see, this appeared to be the original rear crank seal.
While I was looking around, I spotted a couple of other things of interest .....
The bottom edge of the crank position sensor, which I just replaced a few days ago with a new, fresh one. You can see the new oil pressure switch I just replaced, too.
...and the crankshaft position magnet on the flywheel. I doubled-checked and it was very secure in position, so no chance of it coming loose as happens on rare occasions on the M119....
The next step was to check all of the flywheel bolts, which are stretch bolts, to ensure they were still within MB's published spec. In May 1995, MB went to a single-use female Torx bolt, but since my car was made in late 1994, it still used the stretch bolts. These are re-usable as long as the necks of the bolts are within MB spec, with is 8.0mm or higher (up to about 8.3mm). 8.3-8.5mm is what they come as new from MB.
Here are a few photos of me checking the bolts with my caliper. Three of the bolts were 8.0, and the rest were either 8.1 or 8.2mm. I decided since they were all within spec, to re-use them. The bolts will get torqued to 45 Nm, and then angle-torqued 90 degrees when re-fastened to the crankshaft.
Then it was time to remove the actual rear main seal, and its cast aluminum carrier. I purchased a new carrier (and seal) because these carriers can warp and leak, and being a $35 part or so, seemed a no-brainer to replace proactively. The bolts that held it to the block were only torqued to 9-10 Nm, so about the same as the transmission oil pan.
Once the bolts were removed, I used the end of an Allen key to wedge one side of the seal carrier away from the block. Immediately a gush of motor oil started leaking out the top of the pan (remember the engine is mounted at an angle in the 124 with the M104). Luckily I had my oilpan and rags handy, so I didn't get too oily. Nevertheless, I drained the main oilpan from the drain plug to lower the oil level in the pan to stop the seeping from the seal carrier, which it did after a few minutes.
Here's what the rear main seal and carrier look like when removed from the car.
And a few comparison shots of the old and new. The old one has a 1994 date code; the new one has a 2012 date code. The original seal was a Bruss brand; the new one is an Elring, made in Germany.
And then it was time to install the new Elring seal into the new carrier. I did this carefully with a rubber mallet and even blows of moderate intensity, all around the circumference of the seal until it was properly seated in the carrier.
Next up came some "housekeeping" chores. Mainly, I needed to clean up the area with a bit of brake cleaner (keeping a rag stuffed in the area where the oil ran out of the pan, to keep brake cleaner and debris from getting into the oilpan). I also checked the end of the crankshaft for a groove left by the previous seal. Luckily feeling it with my fingertips and fingernail, there was no groove, so it was fine to use the "original" type of seal instead of the "repair" type that I had on hand just in case.
After that, I cleaned up the sealing surface on the block of old sealant with a razor blade, to make as optimal a sealing surface as possible. Then I applied the black MB RTV gasket sealer with my finger to the seal carrier. Sorry that I could not get a photo of this step. Per the factory procedure, I also coated the inside edge of the seal lightly with some motor oil to help it slip over the end of the crankshaft easier.
And here I am fitting and bolting the new carrier into place. The torque rating, as mentioned earlier, is very small -- under 10 Nm.
After the seal and carrier were fitted and bolted down, I turned my attention to replacing the oxygen sensor. It will never be as readily accessible as it was tonight, with the car's exhaust laying on the ground. I need to unplug it inside the car and thread the new O2 sensor through the vehicle's floor. I will do that on Saturday.
The last task of the night was to prepare to run the engine, to check for leaks at the newly replaced main seal. For now, given that I was wrapping up for the night, I just re-attached the flywheel. I will re-torque it down in the morning, and add more engine oil before temporarily attaching the starter and starting up the engine and letting it run for a few minutes.
And that was it for the night. To be continued starting tomorrow......
Cheers,
Gerry