Swapping from Manual to Auto Transmission - Mercedes 722.6 (Week 9 & 10)

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Volvo TGB 13
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Mercedes 722.6
Auromatic Transmission

[@mabs503]

Regarding brake lines. I would put a bit of rubber hose around the areas behind the hoseclamps. The copper is easy to rub through, so any vibration could be bad in the long run.

[@RickCuijpers]

Maybe a 3d printed support for the brake lines clamps; then the brake lines will be satisfyingly spaced.;-)

[@grahames9228]

I don't think the average week-end mechanic would tackle the transmission rebuild. Well done.

[@TheOutFit]

Thank you Grahame for the support!

[@chaosstate4491]

I agree mate. This is impressive.

[@OliReu]

totally agree - seeing other videos of auto trans rebuilds they are a technical beast of a thing.

[@1sheinz]

35 year Glazier here, any shop that cuts glass for houses can order tempered glass in any type or color you want. There needs to be rubber between the copper and stainless clamps. They will corrode the copper quickly as well as wear the copper with vibration, at least 2 layers of bike tubes around the stainless clamps. I'm also competent mechanic and did my first auto transmission last year. I had it apart and back together 10 times at least, and in the vehicle and tested and then back out and apart again too find the piston seals on the clutch drums were torn. They go in backwards and need a tool called a LIP WIZARD, to install. It's basically a 10-12 inch circle of thin ptfd or hmwp and you use it to ease the seals into the piston without tearing them by ROLLING the circle around the lip carefully folding the seal into the cylinder if the drum. Have an extra seal kit ready as you may need it. CHEERS Steve h

[@sultanamajam9725]

Hi.....Awesome-build..... Don't Forget to Add an Extra Mercedes-Benz OIL COOLER for the gearbox and also one for Engine-oil. .....to Avoid overheating.

[@karmann1799]

I applaud you. I am not a mechanic, but will have a crack at fixing anything. An auto gear box tho i will NOT go any where near besides sump removal, oil and filter change. To much to go wrong with those buggers.

[@PeterHatch-mx7zc]

Hope you put a jack stand in your tool kit for out on the road ! Projects 👍

[@Maximus-zm2jp]

I'm glued to this channel every week I'm not technically minded regards vehicles etc . but really enjoy this build .... You certainly know your stuff ... And I'm learning a few basics also . curious to find out what colour vehicle will be ....

[@TheOutFit]

That is very nice feedback to read, thank you so much for watching and commenting! What is your guess for the paint colour? :)

[@ihmesekoilua]

Rebuilding a transmission is pretty hard core. I remember just taking out and replacing the auto box on my discovery was a pretty big job, and frankly having it opened up and resealed by a professional gearbox shop wasn't actually particularly expensive. On a completely unrelated note; I see you've decided to speak English with Oakley. Your decision to make, obviously, but I speak Swedish with my boys and my now-ex wife speak Finnish with them, and they are pretty much completely bilingual. Can't be a true globetrotter without speaking French! :P

[@TheOutFit]

I (Ange) have left France more than 10 years ago so I don't speak French as fluently as English (it's weird but I now think/dream/count etc in English). But I still speak French (I usually do both languages) to Oakley, not on camera though but can do a little clip at some stage :)

[@banjomaisey9050]

Good on you digger,great effort.

[@TheOutFit]

Thanks a lot for following along!

[@MyMd1111]

LOL, I thought you are a mechanic. Go for it Bro. I'm a liitle bit envy.

[@krikkenstein]

Your a brava man 😀 Nice to tag along your mechanical adventures…

[@TheOutFit]

Thank you for following along Erik!

[@grahamjones5378]

As long as the head gasket is OK I would not be tearing down the OM60x engine. Also the 722.6 is prone to flaring the gear change 4th to 5th using aftermarket TCU which can be fixed by making a certain hole bigger in the valve body.

[@seanchristie7150]

Love your confidence and attitude towards the rebuild of the Volvo and various crucial parts on the vehicle. As per a lot of other comments I would be putting Rubber between the copper lines and the SS straps due to any vibration and dissimilar metal corrosion. Keep up the awesome work. Best of luck on the Inspection

[@TheOutFit]

Thank you so much for following along every week Sean! Have a good weekend :)

[@seanchristie7150]

@@TheOutFit doing my best amd Happy Mother's day to Ange for tomorrow

[@jimstelfox6120]

I had a Chrysler 300c that had the diesel 3.00 V6 engine with the auto transmission, it pulled what is a heavy estate in all gears very well and I never had any trouble with it

[@michaelfuchs5034]

Nice I quite enjoyed this weeks video. Cheers

[@TheOutFit]

Thank you so much for following along every week Michael! Have a good weekend :)

[@iandibley8032]

Hi Chris ,very brave attempting an auto rebuild without experience & equipment. Manual gearbox rebuilds not so much chance of getting into trouble. Good luck, hoping you don’t need it.

[@TheOutFit]

Thank you for watching, hope it all goes (relatively) smoothly 🤞

[@Olaus_]

Glazier = Glasmästare in Swedish. You should be able to find one easily in Malmö with that. A company that I have dealt with before and been happy with is "Ryds bilglas" and they have six different shops in just Malmö, so there should be one close to your location. Good luck!

[@TheOutFit]

We'll contact them today thank you for the recommendation!

[@HAESTAREFINA]

@@TheOutFit Carglass is another one if Ryds bilglas does not work out

[@warrengage9536]

Great build, and you're braver than most to tackle any gearbox, never mind an auto. I would suggest you have the torque converter checked. Been there done that. Not fun pulling out a box again just to sort it out.

[@rogergregory5981]

Builds going really well now 👍🏻 your hard graft if paying off Regards glass, in the UK I know you can get 4mm laminated glass to made to size and not to expensive last time I had some, might be a safer choice must be someone there that supply it it's used for security in shop and office windows

[@TheOutFit]

Thanks a lot for following along!

[@philpoole5670]

Love the honesty about being a novice and yes I agree great to challenge yourself … all the best in the rebuild … brave man

[@TheOutFit]

Thank you so much Phil for your support!

[@davidthornborough3395]

Hey Chris ,your doing a fantastic job ,everyone learn from the beginning so dont feel as if your out their on your own .experts come from repetition and repairs.so what you are researching gives you what you need.Ange Oakley is growing so much and even though he may not remember everything this is fashioning his future.Be a proud mom .stay safe enjoy and Chris soldier on ,you are doing great .cheers

[@TheOutFit]

Thank you so much David for your ongoing support, hopefully it's smooth sailing ahead 🤞 have a great weekend!

[@IanDerybshire]

Excellent, you're a braver man than me. Frustrations like the fuel problem pale in comparison to the drugery and mental fatigue of sitting in a cubicle in a massive office complex 9 to 5, Mon to Fri. You're living a unique life, which is what life is all about. Clearly you've done lots of research, have faith in yourself, your knowledge and skills will only improve. The little chap is growing like a willow! Cheers Ian

[@TheOutFit]

Thank you for watching and commenting every week Ian, we really appreciate the support!

[@user-ky4rz2sn8v]

Hey guys, welcome back your doing a great job Chris . Good luck for the rest I’m shore it will work out well😂😂🥴🥴 take care Jon🇦🇺WA

[@bobhudson6659]

Please wrap each brake pipe in rubber before you put the hose clamp around them. Get a short length of rubber hose, about 40mm long (use rubber not plastic - plastic hardens after a while - small dia fuel hose works well), cut/split the hose down the side and wrap it around each brake pipe. If there is a chance that the hose might move, wrap each end with some electrical or even 100 mph tape (look that up if you are not familiar with it). Do the same wherever a brake pipe might chaff on any other part. To not do so is to ask for trouble. You will be travelling over roads/corrugated goat tracks in the future and the vibration of steel brake pipe against anything else is to have the brake eventually wear through - that's not a good thing in the middle of nowhere. Same goes for fuel line or any other auto trans cooler or power steering line. When you fit the other motor watch for possible chaffing on top and bottom hoses plus any heater hoses (use old radiator/heater hose and split them - and tape them to the original hose to stop them moving out of place). On the electrical side, do the same for each cable. Chaffing is your worst enemy. 2nd last thought. Check all flexible cables/brake hoses on full suspension travel as well as full steering lock to each side. Last thought. Also check that your hose clamps can't move sideways out of your desired position. If they do, then all your work on protecting the brake pipes and whatever will be nugatory. All of these measures are preventable. Also just heard you say that your brake pipes are copper. In Australia that is absolutely illegal. Copper work hardens and quite soon, with normal vibration in a vehicle, the flared end of the pipe as it joins whatever it is attached to will break off. Even if it not illegal over there remake all your pipes in specifically manufactured brake pipe. Where you are going is not going to be normal highway driving and pipe ends will break off even sooner. Retired mechanic/machinist in Land Down Under.

[@iandibley8032]

Copper Nickel brake lines are legal in Australia. Nickle adds strength to the copper. I agree protecting the brake lines from the hose clamps in a must do.

[@bobhudson6659]

@@iandibley8032 Agreed re copper nickel, but he only mentions copper.

[@TheOutFit]

​@@bobhudson6659they are copper nickel

[@XerxesGustav]

@@TheOutFit biltema has mounting clips for brake lines, part number 66-444

[@LAP1050]

Chris and Ange, your positive attitude will bring you great success in this new adventure. Sounds like Oakley (little man) will be talking soon and that’s going to add to the fun of watching. Chris, reading the comments you’re getting and sounds like many of the recommendations make good sense. Looking forward to the next video 👍 All the best Lou from Miami 🇺🇸

[@outback3791]

ON MY TGB1314 I REMOVED MY TANK AND TOOK IT TO A RADIATOR SHOP AND HAD THE BOIL IT OUT. ALL FUEL ISSUES GONE! THERE ARE TWO FUEL FILTERS ON THE VOLVOS. ONE IS ON THE FRONT OF THE FUEL TANK AND OF COURSE THE GLASS ONE IN THE ENGINE COMPARTMENT.

[@masafajunior]

Hey chris and angie it's watching from Kenya and you guys are doing good....cant wait for the interior build.....always my best part😊😊good luck in this project guys

[@TheOutFit]

Thank you so much for watching from Kenya! For now we focus on the mechanical side of the build but hopefully we can start on the camper soon :)

[@Vince1266]

Hammer and DOLLY, the door cards are probably made from Masonite, it's used a lot in the building game as permanent packer, it is inert and doesn't rot if it gets damp. Split rubber hose over the brake lines will stop any freating.

[@nickkautzman9711]

Looking good. Always nice to stop in and watch the progress on the overlander and see the family. The wife and I are taking delivery of our 4x4 sprinter next weekend and looking forward to the buildout. Our project is much less ambitious, as fingers crossed all the mechanicals are in good shape. Cheers.

[@TheOutFit]

Thank you so much for watching! Wishing you all the best with your own build :)

[@philhealey4443]

From bad experience, organic sludge in the fuel tank blocking the outlet strainer and filters, , porous hoses letting air into the fuel lines, cracked or corroded fuel pickup pipe, blocked tank vent causing a vacuum and loose hose connections are all good sources of fuel trouble.

[@dangermouse3619]

Make a spray booth with either cheap wood or PVC pipe and clear plastic wrapped around it to work in the gearbox if worried about contamination.

[@Rexy888]

Im really enjoying this build thanks for the effort you both put in too the videos.

[@TheOutFit]

Thank you so much for taking the time to comment, it's really motivating to read positive feedback!

[@andrewjones-productions]

I think that you are doing a wonderful job. I don't know what the Swedish regulations are pertaining to rear tail lamps on older vehicles, but I think that you may be better to check as to whether you need a rear fog lamp and a high mounted rear third brake light. Typically, these are required on European vehicles and since you are re-registering the vehicle, you may find that you need to have those. There again you may not, but that 50-:50 of may or may not is perhaps why you should check. If you do need them, the fog lamp will need to be on the left (driver's side) and the reverse lamp on the right for LHD/RHT countries such as Sweden. There is also no need to temporarily swamp them around if travelling through the UK. Ireland or Malta and the vehicle is on Swedish number plates.

[@TheOutFit]

Thank you so much for the kind words! We have done quite a bit of research and asked other TGB owners what the local requirements are for the inspection so hopefully we got everything covered 🤞

[@jasonlindamood5535]

You are a little crazy! Do it man! I love it! You can do anything!

[@TheOutFit]

Thanks for watching and commenting Jason!

[@craigtuck1741]

great job Chris you are a inspiration to everybody for having a go and doing it very well. keep up the great work and cant wait to see more

[@TheOutFit]

Thank you so much Craig for the kind words, it means a lot!

[@daolman8226]

HEY!! just FYI for future reference...IF your transmission ever stop shifting correctly or stop shifting all together, check your TCM box (transmission control module) if it has one on that year, if the seals inside Mercedes transmissions go bad and this may sound crazy, fluid can travel through the electrical wires of that large electrical plug on your transmission up to the module, filling the box with fluid and short circuiting it.

[@johngibson3837]

Hey up for your glass, I replaced a large rear window on unimog, take the acrylic template to a window shop they can cut and drill in my case, then they send it off for tempering, my one £50 about 8 years ago probably same area as your rear one. With those clamps on the brake lines you need some rubber blocks that go round the lines or they will rub through, the little volvo I getting there

[@hakansundstrombmwsweden7645]

Nice to see you guys are making some real progress, sound and heat insulation is a good idea, I remember the tgb11and 13 as a bit on the Loud side.....

[@TheOutFit]

Thank you so much for following along!

[@Mr_Springy]

Regards your brake lines buy some rubber tubing cut it into 25mm lengths then slit it along its length so you can slide it over the pipes and into position between the clamps and the axles then retighten the clamps. As it is there is a potential for frictional abrasion which will puncture the pipes, especially if you are going off road. Keep it going 👍🏻

[@davidmilledge221]

A support vehicle with flashing lights is normally behind the vehicle that needs support warning motorists that are behind I guess that's why the cops got confused thinking ange is holding you up because she's in front 😂 I'm not sure about stainless hose clamps holding soft copper brake Lines it can wear through in time be interesting if they pass that hmm , I know Regency Park inspection place in Adelaide Australia wouldn't pass that their fussy buggers

[@TheOutFit]

I'll drive behind Chris on our next drive to the inspection, hopefully it goes more smoothly 🤞

[@clasnyberg6592]

Good luck tomorrow! Agree with comments on isolating brake lines from clamps with rubber, might even fail the inspection.

[@MikeBanks2003]

I hope you also used the Merc diesel? I have a SSangyong Kyron turbocharged 2.7 litre diesel vehicle which has a Mercedes Benz motor and transmission, and it sounds like you have the same gearbox as mine has. It was used in everything from small farm trucks to sports cars--probably one of the best transmissions they ever made, but you have to do a trick with the connection plug otherwise it will leak fluid eventually into the computer. I put a thin wafer of Araldite around the pins on the OUTSIDE of the plug, just as an extra precaution. I strongly recommend you DO use the Mercedes transfer case--it is really solid, I can not imagine anything else being any better. There are a few damaged SSangyong Kyrons around going for a song--not not all of them have the four, five or six pots turbocharged diesel. My transmission can be used as an automatic or as a manual, but the automatic is just fine and since it is in use in the manual mode regardless, one might as well use it as an automatic. To switch to manual shifting, one merely puts the vehicle into drive, then push the selector to the left, and you now control the gear change either from a button in the selector handle or racing car style on the steering wheel, take your pick. I think I have used "Manual" it only in rough country when towing. I in most cases I use the full auto mode. I recommend you install an oil catch can after the turbocharger and before the intercooler. I change the lifetime fluid every forty thousand kilometers. As an additional precaution, I open the sheath of the cable that goes to the computer under the seat and making a mould from a plastic pipe, using Blu-Tack as a seal around the wires, I flood the opened-up cable and around the wires where they go into the cable with epoxy resin as a stop-everything except electricity and when it has cured, tape it all over with polyisobutadeine self- amalgamating tape such as Rotunda tape. When that is done, wrap it in some shielding abrasion-resistant tape. If you make such an oil-dam and use epoxy in the plug, there is no way in hell your transmission computer will get flooded with transmission oil.

[@nicholasallez7856]

Hey Chris, there is a place call OF gear in Copenhagen that do the transmission control unit. If you are using the OM606 there is Baldurs control systems in Iceland that do an ECU so you can run the edc pump. The baldur unit can talk to the OF unit so they work together. If you keep the edc you can run cruise control and some other modern goodies as well as monitoring through the obd connector.

[@rickt7425]

Auto ! Great idea

[@HenkTheCamperTank]

Awesome to see the progress! You fly through the tasks :D

[@TheOutFit]

Thank you so much for watching! Hope Henk is behaving well 😄

[@HenkTheCamperTank]

@@TheOutFit Yes he is! Preparing him for the besiktning as well 😄

[@warth09]

Nice, "trondheim bildemontering" my hometown.

[@tage-karlsson5237]

Nice to meet you today. Admiring your work. Good luck.

[@packepuck]

I guess you are looking for a "glasmästare" to replace those acrylic windows.

[@TheOutFit]

Thanks for the help!

[@andersholmstrom3571]

I hope you had a guided tour of the castle. It is really well worth it. You get so much more out of your visit. And I hope you went to the Kalmar museum. It has a lot of greatr stuff about the "Regalskeppet Kronan".

[@TheOutFit]

No we didn't get the guided tour but with Oakley it may have been a bit tricky. We look forward to visiting more castles in Sweden now :)

[@andrefischer5025]

Can you let us know a little about how you ended up choosing the engine/gearbox combo? Love the door card refurb/reuse, great option!

[@TheOutFit]

That's a good question Andre! Chris will address this in more details in the next episode :)

[@joeljakobsson7516]

glad you liked Kalmar city( I live here), it is e pearl during summer so it will only get better, and keep up the good work!

[@TheOutFit]

We are glad we visited Kalmar, we had a great time :) thanks for watching!

[@endotasweegin6613]

Chris you need to secure those lines differently mate, think of the vibration it's subjected to, those hose clamps will destroy those lines in no time. Look at what is used oem and copy

[@davidthornborough3395]

Thanks

[@anfieldroadlayoutintheloft5204]

good vid on the build keep up the good vid on the channel thanks lee

[@TheOutFit]

Thank you so much for watching and commenting Lee!

[@paulnoneofyoir8506]

Hi I agree with @mabs503 below about putting some rubber hose pieces around the copper brake where you have them clamped down and rubbing against each other . Most causes of death in an auto trans is heat related , so fitting a good aftermarket transmission cooler and electric fan . When you in the middle of summer crossing a desert through a bunch of sand, mud and other nasty stuff the oil in that trans is getting really hot and that heat is what kills the electric components in the tranny . Another good thing is to add a trans oil temp gauge . And do the research on trans oil temp .Hope this helps

[@ChristofferLofstrom_]

Check the fuel tank. there is a coating that comes off on the inside of the older tanks that cannot handle ethanol. Tatanka has new stainless steel tanks they are not cheap but you won't have that problem anymore.

[@user-ky4rz2sn8v]

Hey Chris, don’t forget to cover those break lines .🥴🥴Jon🇦🇺WA

[@CptAwesomedude]

It helps if the gloves are not completely destroyed! also you might wanna use the vaselin on your "old man hands" ;)

[@shoffman75]

I would replace the torque converter. You already have it out. No better time.

[@coloradoridgerunner791]

Question aren't you worried about causing corrosion on the brake lines using those steel hose clamps? When steel is directly connected to copper, copper galvanic corrosion occurs.

[@Coffe-]

Spend some time finding a machine shop now so you don't have to wait in line. Waiting time can be 3-12 months.

[@rhyswilliams695]

Well done Chris. I wouldn’t have the courage to overhaul an auto. Wouldn’t it be easier to use the MB transfer case?

[@mozkotze6415]

Pilkington glass UK will do and make anything you require and ship all over Europe at a reasonable price

[@TheOutFit]

Thank you for the recommendation :) We'll try to find one locally but otherwise we'll contact them.

[@Lee-in-oz]

Yep that's the first thing you do to check the fuel pump. Belt the tank😊😊😊. I seriously think you could RPL your mechanics apprenticeship based on the work you have put into both the Mog and the TGB. Also, I don't know if I should be impressed or disappointed that none of the bolts ended up in the drip tray... Got a question, I have been rewatching the Mog Build and just wondering what did you use to secure the aluminium framing to the roof and walls of the box?

[@TheOutFit]

We used Sika 111 Stick & Seal, highly recommend!

[@davidmilledge221]

Amazing video guys gee your in deep now buddy with things good luck 👍🙏 , ive noticed you both have rings are you guys secretively married 🤔

[@TheOutFit]

We got engaged in June 2022 in Spain and got ring tatoos then :) we will probably elope at some stage!

[@KevIsOffGrid]

So, Merc transmission, maybe it is a OM606 like I initially guessed. Confused me last time with the auto reveal and thought maybe BMW M57.

[@panc4kes347]

I hope you are bolting a OM606 to it

[@jong7258]

Sorry to say, but the 5 speed from MB.is a known BAD Transmission, and the 7 & 9 speed (newer ones) is known to be very good.!

[@aucarreau]

♥

If you your going to all the trouble of stripping down a complex auto trans, why would you not replace all the bearings? You cannot visually inspect the internal race of the bearings. Play it safe. Replace them all. Be careful paint the bare aluminium transmission casing as it will alter the thermal transfer of the aluminium and will cause the transmission to run hotter than designed, this is the reason that they are not painted from factory.

[@FelixAustralis]

My thoughts exactly regarding painting the gearbox. I was on an overland trip years ago and one of the Land Rover crowd was having trouble with changing gears and blowing oil everywhere. Arrived in Peshawar and the mechanic looked under the car and started mumbling about paint. The gearbox was taken out stripped of the paint - coarsely sandblasted and all problems magically disappeared. Look up Rolls Royce and the GM gearbox story - overheating 'hydro-matic' boxes after RR polished all the roughness off them to make them look 'nice'. The gearbox is designed to shed heat and the cooler helps the heat from the torque converter. No paint - please.

[@theyorkshirediyguy]

I’m guessing he’s going to use a Mercedes om605 with mechanical 6mm pump built by dieselmeken and the dsl1 gearbox controller from baldur??

[@dunniss]

When is the OM617 going in?

[@marcovanstaden45]

I’m guessing an OM606 engine

[@degodiego7376]

Ya no salen los subtítulos en español 🥲🥲🥲

[@HowardMcNeil-ce6ij]

total cost

[@sibhs66]

Are you in Eurovision town? Busier than normal? Marty from Perth

[@TheOutFit]

Yes we are just outside Malmö but we haven't been in town just in case because of all the protests etc!

[@andersjonsson7218]

-"Long life oil....", that´s BS. You right, change oil and your equipment will work properly

[@pwatom22]

Why replace a basic solid Volvo manual box with a Mega Bucks auto?😐

[@TheOutFit]

Chris will address in more details in the next episode but we didn't want to keep a 4 speed transmission.

[@crabapple1974]

Too bad about unfriendly police, usually they are nice and professional. Ice to follow along, living in Malmö but grew up partly in Kalmar. Kalmar is beautiful, Malmar was the seat of power of Scandinavia in the Middle Ages (Kalmar-unionen). Kalmar and Öland is awsome in summer.

[@TheOutFit]

We look forward to visiting more areas in Sweden :) we'll probabky go near Gothenburg next!

[@fransjanssen2198]

Mercedes transmission in a Volvo?! What the f*ck Chris, that's blasphemy. Why didn't you buy Mercedes? AW71 transmission is bullitproof, you know. Now I'm holding my breath for the engine you want to hang in. Personaly I would think twice about taking the gearbox apart, that's real work for specialists, that's my experience. Keep up the good work!

[@warrengage9536]

Cops probably didn't worry about you because they assumed it was a military vehicle...

[@TheOutFit]

The camo colour helps!

[@chrisdaniel1339]

Manual transmissions are more rugged and there is less that can go wrong in the back country, why would you ever want an automatic transmission?

[@TheOutFit]

Chris will address this in the next video but this transmission "bolts in" on the new engine we got.

[@chrisdaniel1339]

@@TheOutFit Why not have the old engine decked/machined, cylinders bored one size over and honed, new cylinders/new rings, new bearing all around, new cam shaft(s) if necessary, new oil pump, timing chain, etc so that it remains a numbers matching historic vehicle?

[@aucarreau]

Je peux seulement parlé 'pétanquois´- would be nice to hear some French. And accent! Please speak French to your son!

[@rickt7425]

Yes, that is a very good idea