Sealing Intermediate Plate
Sealing Intermediate Plate (A4S 270R/310R)
(transmission removed, refer to Removal and Installation) Removing and Installing Automatic Transmission
Secure transmission to assembly frame with special to 24 0 150 / 154 / 155.
Drain off transmission oil.
Screw special tool 24 4 000 into torque converter and withdraw torque converter.
Unfasten retaining screws on radial seal.
Remove radial seal with special tool 00 5 010 and an appropriate thrust piece (1) from converter bell housing
Remove oil pan (1).
Note: When cleaning the sealing faces, ensure that no seal residue drops into the transmission.
Set transmission upright (converter bell housing facing upwards).
Remove O-ring.
Unfasten screws with special tool 24 5 180.
Lift converter bell housing off with oil pump.
Remove shim (1), seal (2) and seal (3) from oil pump.
Note: When cleaning the sealing faces, ensure that no seal residue drops into the transmission.
Caution: If the transmission serial number is higher than 4 834 735, ignore the next three work steps.
Remove rectangular rings (1) from turbine shaft (2).
Coat new, open plain compression ring (1) with petroleum jelly and insert in lower groove of turbine shaft (2).
Coat new, closed plain compression ring (3) with petroleum jelly, widen a little and insert in upper groove of turbine shaft (2).
Slide special tool (1) over plain compression rings until special tool (1) is resting on freewheel housing (3).
Note: Special tool is contained in repair kit.
The special tool (1) must remain fitted for at least 5 minutes to ensure that upper rectangular ring is pressed into groove.
Therefore do not remove special tool (1) from turbine shaft (2) during subsequent work.
Lift turbine shaft (1) with idler (2), spacer ring (3) and disc pack (4) out of intermediate case (5).
Remove axial needle bearing (1), ring gear (2) and step disc (3).
Remove thrust washer (1).
Release screw and allow cable plug (1) to hang from side.
Remove cable connector from solenoid valve.
Lift intermediate case (1) from main case (2) and withdraw cable from intermediate case.
Note: To clean sealing face (1), place transmission on level ground to ensure no seal residue drops into the transmission. Clean threaded bores.
Take off spacer (1).
Remove plain compression rings (2).
Press down spring retainer (1) with special tool 24 2 311/24 2 312 until strain is removed from snap ring (2).
Caution: Do not press spring retainer (1) down too far - risk of damage.
Remove snap ring (2).
Remove special tool 24 2 311/24 2 312.
Remove spring retainer (1) and snap ring (2).
Remove compression springs (1).
Withdraw piston (1) from intermediate plate (2).
Unfasten screws with special tool 24 5 180.
Remove intermediate plate (1) from intermediate housing (2).
Remove gasket (1), intermediate panel (2) and gasket (3) from intermediate housing (4).
Insert special tools 24 2 313 in intermediate housing.
Note: Oil restrictor (1) must be in the bore that is shown.
Position gasket (1), intermediate plate (2) and gasket (3) on intermediate housing in accordance with hole pattern.
Note: Gaskets (1) and (3) are identical.
Mount intermediate plate (1) on intermediate housing (2).
Tighten screws diagonally and evenly with special tool 245180.
Tightening Torque: Mechanical Specifications
Remove special tool 24 2 313.
Replace sealing rings of piston (1) and coat with petroleum jelly.
Attach special tool 24 2 314 to intermediate plate (1).
Press piston (2) into cylinder of intermediate plate (1) a far as it will go.
Remove special tool 24 2 314.
Insert compression springs (1) (24 x) in piston.
Place spring retainer (1) on compression springs.
Place new snap ring (2) on spring retainer (1).
Press down spring retainer (1) with special tool 24 2 311/24 2 312 until groove for snap ring (2) is free.
Caution: Do not press spring retainer (1) down too far - risk of damage.
Insert snap ring (2) in groove.
Remove special tool 24 2 311/24 2 312.
Secure shim (1) with Vaseline.
Coat new plain compression rings (2) with petroleum jelly and insert in grooves.
Screw centering pins (1) into main housing.
Note: Centering pins are contained in repair kit.
Replace O-rings (2) and coat with Vaseline.
Position intermediate housing (1) on main housing (2) and in so doing feed wires for solenoid valves into intermediate housing.
Connect cable plug to solenoid valves.
Screw cable plug (1) onto intermediate housing.
Coat thrust washer (1) with Vaseline and install in intermediate case.
Note: Locking device in thrust washer (1) must locate in recesses of intermediate case.
Install axial needle bearing (1) with black side facing upwards.
Install ring gear (2) and steel disc (3) in intermediate housing.
Install turbine shaft (1) and idler (2) in ring gear of intermediate case.
Install disc pack in intermediate case (3).
1. Lined discs
2. Steel discs
Install spacer ring (1) in intermediate case (2).
Recess in spacer ring points towards oil pan.
Remove special tool (1) if necessary.
Secure shim (1) on oil pump with Vaseline.
Stick new seal (2) to oil pump housing with Vaseline, carefully aligning the hole pattern.
Coat new seal (3) with Vaseline and place on oil pump.
Mount converter bell housing with oil pump on transmission housing.
Drive out centering pins with a screwdriver.
Tighten screws diagonally and evenly with special tool 245180.
Tightening Torque: Mechanical Specifications
Insert new O-ring in groove of drive shaft and coat with petroleum jelly.
Install oil sump (1).
Note: Replace seal.
Use new screws (microencapsulated).
Insert all screws until contact is made with screw head in each case.
Then tighten all screws in sequence once to specified torque.
Tightening Torque: Mechanical Specifications
Coat sealing lips of new radial seal with automatic transmission fluid.
Insert radial seal in converter bell housing and secure with 3 screws.
Tightening Torque: Mechanical Specifications
Insert torque converter through sealing ring to first limit position on the transmission shaft.
Manually push and turn the torque converter into the converter bell housing until the recess of the converter hub rests in the drive plate of the pump wheel and the torque converter perceptibly slides in.
The torque converter is correctly installed when the gap between surface of threaded bore on torque converter and locating face of bell housing is approx. 31 mm.
Remove special tool 24 4 000.