Part 3 - D Brake/E1/E2 and Planetary Gear Set

Dismantling and Assembling Automatic Transmission (A5S 560 Z)

Part 3 - D Brake/E1/E2 and Planetary Gear Set





- D brake/E1/E2 and planetary gear set:
- Arrange transmission horizontally. Unscrew bolts.

Installation:
- Tightening torque: 25 Nm




- Pull off transmission extension (1).

Installation:
- Replace O-ring
- For ease of assembly, coat O-ring with Vaseline.




- Remove shim (1) and sprag wheel (2). Installation;
- End float is adjusted with the shim (1). Adjust end float, refer to "Replacing Output Flange"




- Arrange transmission vertically with output end facing downwards.
- Unscrew bolts.

Installation:
- Tightening torque:
Use the following sequence:
1. Tighten all screws until contact is made with screw head.
2. Center bolt to 30 Nm
3. Both outer bolts to 15 Nm
4. Center bolt to 63 Nm
5. Both outer bolts to 30 Nm
6. Both outer bolts to 63 Nm




- Screw special tool 24 1 260 into planetary gear set, tighten down knurled screw.

Note: Cylinder D/E (1) and the planetary gear set are held together by tightening down the knurled screw.

- Lift out complete unit with a workshop crane and place on two wooden blocks.




Installation:
- Twist spline (2) with a screwdriver until it locates in housing of planetary gear set (1).




Installation:
- For ease of assembly, coat perimeter of cylinder D/E (1) with Vaseline.
- Align threaded bores in cylinder D/E (1) with bores in transmission case.
- Carefully insert complete unit.

Caution! Do not abut against transmission case.




- Remove special tool.
- Lift off cylinder D/E (1).




Installation:
- Fit cylinder D/E with aligned discs on the planetary drive.
- Twist housing of planetary gear set to and fro briskly until discs on multi-disc brakes engage completely in the spline teeth.
- Control dimension (A) approx. 45mm.




- Lift out snap ring (1) from multi-disc brake D and remove complete disc pack.

Installation:
- Note installation position of snap ring ends.
- Align lined discs.




Installation:
1. Circlip
2. Spring disc
3. Outer discs
4. Lined discs
5. Top outer disc (may be thicker)




- Lift snap ring (1) out of multi-disc brake E2 and remove complete disc pack.

Installation:
- Note installation position of snap ring ends.
- Align lined discs.




Installation:
1. Circlip
2. Spring disc
3. Outer discs
4. Lined discs
5. Top outer disc (may be thicker)




- Lift snap ring (1) out of multi-disc brake E1 and remove complete disc pack.

Installation:
- Note installation position of snap ring ends.
- Align lined discs.




Installation:
1. Circlip
2. Spring disc
3. Outer discs
4. Lined discs
5. Top outer disc (thicker)




- Remove angled disc (1) and axial needle bearing (2).




- Lift freewheel off 2nd gear (1).

Note: Fitted freewheel must lock in clockwise direction and should be easy to rotate in anti-clockwise direction.




- Lift out disc carrier E2 (1).

Installation:
- For ease of assembly, coat disc carrier, O-ring and sealing face with Vaseline.




- Lift planetary gear set I + II(1) off planetary gear set III(2).

Installation:
- Rotate planetary gear set I + II to fit on planetary gear set III.




- Remove sun gear II + III(1) from planet carrier III(2).

Installation:
- Install sun gear, rotating to do so.




- Place planetary gear set I + II on two wooden blocks Lift out snap ring (1) and remove ring gear III(2).

Installation:
- Note installation position of snap ring ends.




- Lift out planet spider II(1).

Installation:
- Replace O-ring.
- For ease of assembly, coat O-ring with Vaseline.




- Remove thrust washer (1), axial needle bearing (2) and angled disc (3).

Installation:
- Note installation position




Note: When removing the sun gear, check whether marking groove in sun gear is facing upwards or downwards. The sun gear (1) must be installed in the same position.

- Remove sun gear I(1) from planet spider I(2).




- Lift out snap ring (1).

Installation:
- Note installation position of snap ring ends.




- Remove planet spider I(1) and ring gear II(2) from ring gear I(3).




- Lift out snap ring (1).
- Remove planet spider I(2) from ring gear II(3).

Installation:
- Replace O-ring.
- Note installation position of snap ring ends.




- Arrange transmission horizontally.
- Unscrew bolts.

Note: If necessary, strike screws when unfastening.

Installation:
- Tightening torque: 23 Nm




- Arrange transmission vertically with output end facing downwards.
- Secure special tool 24 1 280 to cylinder F (1).
- Pull out cylinder F (1).




Installation:
- When installing cylinder F, insert guide bolts in two bores beside bore (B).
- Bore (A) in cylinder F and bore (B) in transmission case must be aligned.




Installation:
- Screw the guide bolts (1) (2 bolts M8x7O without bolt heads) into cylinder F, each next to the bore (A).
- Replace O-ring.
- For ease of assembly, coat grey area with Vaseline.




Installation:
- Freewheel on 1st gear must rotate easily in clockwise direction and should lock when turned anti-clockwise.




- Lift out snap ring (1).
- Lift freewheel for 1st gear (2) out of multi-disc brake




- Lift snap ring (1) out of multi-disc brake F (2) and remove complete disc pack.

Installation:
- Note installation position of snap ring ends.
- Align lined discs.




Installation:
1. Circlip
2. Spring disc
3. Outer discs
4. Lined discs
5. Top outer disc (thicker)