Rebuilding Transmission #4 - Put it back on!

Finally, we put the rebuilt transmission back on my Mercedes. And added ATF (total 9 liters), and, started the engine!
I tested drive it first around the shop at local streets and then I felt quite confident to just hit on the highway. It ran just like a new transmission out of the factory!

The above was before the transmission put back, and I did not take a picture after we put it back, sorry. And I bought a Costco chicken back to the shop to celebrate after the test drive! 

Rebuilding Transmission #3 - Re-assembly back

The third day we first disassembled the main valve body and found it was quite dirty inside, so I have to clean it up thoroughly:

I have to use a cloth and a small tool to clean up all the dirty bits inside the valve body, and not removing any metal balls or spring devices so we won't make mistake when putting them back. And this is how it looks like after cleaning:

After completed valve body cleaning, we started to put everything back together with new gaskets, oil sealing and o-rings, basically in a reverse sequence of disassembling. Every parts were carefully cleaned with gasoline, dried with air gun and greased with ATF before installation back. And we referred to the pictures taken at disassembling so we would not put anything back in a wrong way or position.

This is the special tool to remove oil sealing:

 

Rebuilding Transmission #2 - Disassembly

The second day's job was disassembling the transmission parts in details, step by step (pictures are taken to make sure we put them back in right position and order), and exam the condition of parts, order new parts if needed, and clean up all parts thoroughly.

Removing the main valve body from transmission:

Identifying, taking pictures to record location and position of all small devices in the valve body:

This is a dirty bit (seems like a clutch fragment) I found in the valve body, could be one of the reasons for transmission failure:

Getting the clutch cylinders and everything out:

Disassembled parts placed in order on the rack:

More cleaning:

 A special tool to compress spring cylinders for removing clutches and bands: NT$1,500

Disassembled clutch cylinder with the special tool:

Rebuilding Transmission #1 - Remove and clean up

After fuel pump replacement, it was time to start with transmission.

Removing transmission off my Mercedes is not critical. We spent 2~3 hours in the afternoon for that and then I cleaned it up a little bit. And let's call it a day.

Rebuilding transmission #0 - changing fuel pump

Rebuilding the transmission box of my Mercedes is what I long to do as I probably mentioned in earlier article, the transmission has some problems need to be fixed. I have never done any transmission rebuild before, but I really like to give it a try. So finally, before end of the year, I have gotten a chance to take 3 days off work to complete this rebuild work. And the transmission runs just like new when I put it back on my Mercedes after the rebuild!

Before going to details, I need to give many thanks to Siao Yeh, a professional car repair friend, for providing his repair shop and tools, and his professional assistance while we doing the rebuild together.  Without Siao Yeh, it is literally not possible for me to perform the rebuild.

#0 Changing fuel pump before the transmission rebuild -
My Mercedes has been sitting on the side of the road for quite a while (license plate has been stopped to save tax money since I never really drive it). I had problem starting the engine so it was tolled to the repair shop, and I had to change a new fuel pump to fix the problem.

Old fuel pump is not working...

All BOSCH brand new parts:

 - Fuel pump NT$3500

 - Fuel filter NT$700

- Free labor :-)

Changing turning signal lamp light bulb - Such a nice design!

My big toy has been sitting on my neighbor's land (on top of our hill) for a while now due to engine not starting up problem. I have been busy working on the retaining wall project so have not had time to look at it. 

The weekend before last, my friend Siao-Yeh from repair shop came visit for a barbecue party, so we went up the hill for a look at my Mercedes. It is much easier for two persons to check on the problem than one; one can stay in the car turning the key, while the other one can check on the engine compartment or underneath the car (like fuel pump). And the diagnostic we had the day was either the fuel pump or the fuel pump relay because no fuel has been delivered and there was no operating noise from the fuel pump. And the electric system was all fine.

So last weekend, I went get an old relay from a nearby junk yard, and tried it on. But strangely enough, my MB didn’t start right up with the “new” relay, and instead, it suddenly started up when I put the old relay back! Well, the best guess I have for this situation is - the replay I got from the junk yard is not functioning right (it has a different part number) but the original relay is a bit damaged but not totally broken yet, and just happened to recover its function when I re-plug it back on. So well, since the engine had started, I reckon it would be good to do a warm up run, and put some gas in too.

During the drive, I realized one of the left turning signal lamps must be broken. The blinking frequency was faster than normal pace. And it was the front left one. I happened to have a few spare light bulbs in the trunk, so I decided to change it right away.

Now, this is the part why I have this blog today!

Interestingly enough, I have never change a light bulb for my MB before yet. I picked two kinds of bulbs I have in the trunk, and also grabbed a screw driver since I was expecting to use it; Opened the hood, and funny, I can not find any screws for securing lamp chamber at all. The only thing I can see is a big round hand screw knob (in below picture).

After I tried to un-screw and remove this knob by a hand, the whole turning lamp was released and can be pushed out easily for me to change the bulb!

Wow! Bare hands with no tools required! I have to say I was really impressed by German design.

New front Break System and more Suspension Fix

Despite the transmission problem for the moment, the MB still shakes when stepping on breaks. It is quite obvious the old front break discs from the junk yard didn't seem to work right even after re-surfacing, and neither does the front break cylinders since one side of the front tire is constantly clammed. So a couple of weeks ago, I took my MB to my friends repair shop and ask him to order new parts including all break pads, cylinder pumps and discs, and do the replacement for me.

In addition, some worn rubber joints of the suspension system are also replaced the same time.

After the repair, I test drove my MB last Saturday, and confirmed the shaking problem has been finally fixed!

Total cost for parts and labor this time: NT$11,000

Below are the pictures of new break parts replaced: