Disassembling and Assembling Transmission
Disassembling and Assembling Transmission
- Remove transmission. Removing and Installing Transmission
- Remove torque converter. Service and Repair
- Mount transmission on Special Tool 24 0 150 together with assembly stand.
IMPORTANT!
- Screw In bolts only finger tight to prevent damaging the transmission case.
A) Disassembling:
- Unscrew oil sump.
- Remove oil liter screws.
- Use Special Tool 00 2 100 for Torx screws.
- Take off valve body.
- Unscrew Torx screws with Special Tool 00 2 100.
IMPORTANT!
Only unscrew screws with 12 mm size head (A).
The transmission wire harness socket has to be removed for the version with electronic/hydraulic control (EH).
- Lift out 8 circlips.
- Remove 8 springs.
Installation:
- Install the long springs lacing the output.
EH Transmission:
- Only 2 circlips and 2 springs have to be removed at cylinder F (output side).
- Pull out 8 sealing sleeves with special Tool 24 0 050.
EH Transmission:
- Only 2 sealing sleeves have to be removed at cylinder F (output side).
IMPORTANT!
Lubricating oil supply is Improved for the cylinder F gear set.
Circlip (2), spring (3) and sealing sleeve (4) must be removed additionally at bore (1).
Sealing sleeve (4) must be pulled out of the bore with a M 6 x 65 screw.
Cant screw slightly for this purpose.
- Lift off lockplate.
- Hold output flange with Special Tool 23 0 020.
- Unscrew collar nut with Special Tool 231 210.
- Pull off the output flange.
- Unscrew transmission extension
Installation:
- Replace gasket.
- Loosen screw (1) enough with Special Tool 00 2 100 that bracket (2) can be folded down.
- Remove parking lock pawl, spring and bearing pin.
Caution! Strong spring force.
- Pull off parking lock gear with regulator.
Note:Check axial shim if applicable.
Version with Spacer (5):
- The parking lock gear must be pulled off with Special Tool 23 1 050.
Version with Transfer 8ox:
- Lift out snap ring (1) and slide forward.
Installation:
- Replace snap ring.
- Pull bearing sleeve (2) off of input shaft with Special Tool 008500.
Installation:
- Install snap ring (1) in groove of output shaft.
- Heat bearing sleeve (2) to about 80°C (175°F) with a hot air blower and slide on to output shaft against stop ring (1).
- Lift out circlip (3).
- Pull off parking lock gear and governor.
- Place Special Tool 24 1 010 on output shaft and secure with collar nut.
Note:
For version with spacer (5) a suitable pipe (6) must be used to take up the distance between case and special tool sleeve
- Unscrew Torx screws with Special Tool 00 2 100.
- Set the transmission upright.
- Unscrew converter bell housing and transfer plate.
Note:Only remove inner bolts of lock circle
- Remove angled washer (1) axial bearing (2) and thrust washer (3).
- Remove input shaft with clutch A
- Remove plate carrier (4) for clutch A with angled washer (5) axial bearing (6) and thrust washer (7).
- Remove snap ring (8) with help of two screwdrivers.
Installation:
- Replace snap ring (8).
- Pull out clutch B with two locally made hooks.
Installation:
- Lift clutch until resistance is noticed and push back again.
- Pull out clutch with one firm Jerk.
This will also pull out support (9) and seal (10).
Sketch for load manufacture of hooks. Dimensions in mm.
- Lift out snap ring (ii).
- Apply Special Tool 24 0 040 on the intermediate shaft.
- Pull out entire set
- Remove angled washer (12), axial bearing (13) and thrust washer (14).
Remove 4th gear clutch set.
B) Assembling:
- Install 4th gear clutch set.
- Guide clutch set into transmission case that 4 oil feed bores are aligned with bores in the case.
- Bolt down clutch set with Special Tools 00 2 100 and 00 2 050.
- Tightening torque: Mechanical Specifications
- Set the transmission upright.
- Insert thrust washer (3), axial bearing (2) and angled washer (1) with collar lacing up.
If necessary, hold on connecting shalt of the clutch set with Vaseline.
- Place entire set in case Four oil teed bores must be aligned with bores in the case.
- Springs (1 and 2) must be in center of the cylinder groove.
- Insert snap ring (11).
- Remove Special Tool 24 0 040
- Insert and press clutch B against the stop.
- Install seal (10). support (9) and snap ring (8).
- Insert plate carrier (4).
- Install thrust washer (7) and axial bearing (6).
- Paste angled washer (1) on cylinder A with grease (Vaseline).
- Insert clutch A and move it back and forth until splines of plate carrier and plates mesh.
Note:
Clutch A Is In correct installed position, when distance (B) between cylinder A and case sealing surface is approx. 8 mm (0.315").
- Install angled washer (3) with collar facing up and axial bearing (2).
- Paste on gasket and thrust washer (1) with grease (Vaseline).
- Install converter bell housing and tighten all bolts.
- Tightening torque: Mechanical Specifications
- Check axial play of input shaft.
- Mount Special Tool 24 0 010 to hold the Input shaft.
- Apply Special Tool 00 2 510.
- Check axial play by pulling input shaft.
Specifications:0.2 to 0.4 mm (0.008 to 0.016").
If play deviates, take off converter bell housing and replace thrust washer with a thicker or thinner one.
- Bolt down converter bell housing.
- Tightening torque: Mechanical Specifications
- Remove Special Tool 24 1 010.
- Lubricate 0-ring (3) with ATF.
- Slide on parking lock gear with regulator.
Note:
Install axial shim between the regulator and output flange for the version without a spacer.
IMPORTANT!
Version with Spacer (5):
- Heat spacer (5) to about 80°C (175°F) with a hot air blower after mounting the parking lock gear and push spacer on to the output shaft.
- Install parking lock pawl.
- Connect return spring (1) in bore (2) 0f parking lock pawl.
- Paste on gasket (4) with grease.
- Bolt on transmission extension.
- Tightening torque: Mechanical Specifications
- Install output flange. Screw on collar nut.
- Hold output flange with Special Tool 23 0 020.
- Tighten collar nut with Special Tool 23 1 210.
- Tightening torque: Mechanical Specifications
- Install lockplate.
- Install 8 sealing sleeves.
- Press in sealing sleeves against the stop with a suitable mandrel. - Be careful not to damage the sealing sleeves.
EH Transmission:
- Only two sealing sleeves have to be installed at cylinder F (output side)
- Install 8 springs and 8 circlips
IMPORTANT!
Longer springs must be installed to face cylinder F (output side).
EH Transmission:
Only two springs have to be installed on cylinder F (output side).
Note:
Version with improved Lubrication on cylinder F Gear Set:
- Install sealing sleeve (4) In bore (1) with the tab facing the oil bore.
- Press in sealing sleeve against the stop with a suitable mandrel. - Install spring and circlip.
- Mount valve body the selector valve can be connected in the operating finger of the pawl.
This requires pulling the throttle cable slightly, so that the accelerator cam does not clamp on the throttle pressure valve.
- Screw In mounting bolts for valve body.
IMPORTANT!
Bolts differ In length.
Bolts (1) - 65 mm long.
Bolts (2) - 60 mm long.
- Align valve body with Special Tool 24 3 050.
- Distance between valve body case and throttle pressure piston must be 11.5 mm (0.453").
- Tighten valve body bolts with correct tightening torque: Mechanical Specifications
- Tighten bolts with Special Tools 00 2 100 and 00 2050.
EH Transmission:
- Check 0-ring (4), replacing if necessary.
- Insert socket with flat side lacing out and bolt.
- Tightening torque: Mechanical Specifications
Note:
- Also mount pulse sender on control unit.
- Engage tabs of holder (5) In grooves of plug.
- Install O-ring (1) between valve body and oil filter screen.
- Install and bolt down oil filter screen.
- Tightening torque: Mechanical Specifications
- Check length of bolts.
- 65 mm long.
- Place magnets (1 and 2) in oil sump.
- Install gasket (3).
- Install oil sump and tighten bolts with brackets.
- Tightening torque: Mechanical Specifications
IMPORTANT!
Both brackets with straight, short legs must be mounted on straight side of the oil sump.