Part 1
Dismantling and Assembling Automatic Transmission (A5S 560 Z)
Part 1
- (transmission removed)
- Secure transmission to assembly frame with special tool 24 0 180.
- Drain off transmission oil.
- Screw special tool 24 4 000 into torque converter and remove torque converter.
Installation:
- Push the torque converter through the sealing ring until it reaches the first stop position on the gear 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 distance between the surface of the tapped hole at the torque converter and the contact surface of the converter bell housing is approx. 29 mm.
Caution! If the torque converter is incorrectly installed, the drive plate of the oil pump will be destroyed when the transmission is bolted to the engine.
- Unscrew bolts and remove oil pan.
Installation:
- Clean sealing surfaces.
- Use new gasket.
- Tightening torque: 10 Nm
- Remove oil container (1) with magnetic disc (2).
Installation:
- Clean magnetic disc.
- Unfasten screw and remove impulse sensor (1) and retaining clip (2).
Installation:
- Note cable routing.
- Tightening torque: M5 = 6 Nm / M8 = 23 Nm
- Unfasten screws and remove oil strainer.
Installation:
- If necessary, replace oil strainer.
- Tightening torque: 5 Nm
Installation:
- Replace O-ring.
- For ease of installation, coat O-ring with Vaseline.
- Remove retaining clip and press cable connector into transmission case.
Installation:
- Note installation position in connector housing.
Installation:
- Replace O-rings.
- For ease of installation, coat O-rings with Vaseline.
- Unfasten all screws with large heads (12 off) Lift off shift unit.
Installation:
- The shift unit must lie flat.
- Evenly tighten down screws in several passes.
- Tightening torque: M6x12 = 6 Nm / M6x55 = 8 Nm
Installation:
- When fitting the shift unit, insert spigot of detent disc in groove of slide valve.
- Remove suction and pressure pipes from shift unit and replace all O-rings.
Installation:
- For ease of installation, coat O-rings with Vaseline.
- Install the suction and pressure pipes into the transmission housing.
- Upend the transmission (converter bell housing upward).
- Unfasten retaining screws on oil supply unit.
Installation:
- Replace sealing rings(1).
- Screws (2) on oil duct M6 x 65, remaining screws M6 x 40.
- Tightening torque: 10 Nm
- Clamp special tool 24 1180 on stator shaft.
- Remove oil supply line from transmission case.
Installation:
- Replace O-ring (1).
- Replace damaged rectangular rings (2).
- For ease of installation, coat O-ring (1) and rectangular rings (2) with Vaseline.
- Push the rectangular rings (2) flush into the grooves.
- Suction and pressure ducts in oil supply unit must be aligned with bore in transmission case.
Caution! If the rectangular rings (2) are too high, they can be damaged during the installation of the oil supply unit.
- Remove adjusting disc (1), needle bearing (2) and angle disc (3).
Installation:
- End float is adjusted with shim (1).
Installation:
- Adjust end float:
- Install and tighten down oil supply unit.
- Secure special tool 24 0 012 to stator shaft.
- Fit and secure special tool 24 0 011 with dial gauge to the input shaft.
- Fit measuring probe to special tool 24 0 012 with slight pre load.
- Zero measuring scale.
- Withdraw input shaft as far as stop and read off measuring value.
- Adjust end float to 0.10-0.30 mm.
- If necessary, remove oil supply unit again and install thicker or thinner shim.
Installation:
- Check with special tool 24 3 140 that pump wheel on oil pump is able to rotate easily.
- Unfasten screws (A and B).
Installation:
1. Tighten screws (A) M6x40 crosswise to 10 Nm
2. Tighten screw (B) M5x50 to 5 Nm
- Remove oil pump from oil supply housing with cotter pin extractor and plastic hammer.
Installation:
- Insert dowel pin (1) in oil supply housing.
- Replace O-ring (2).
- For ease of installation, coat O-ring with Vaseline.
- Screw assembly tool (3) (two M6x6O screws without screw head) in pump housing.
- Remove pump wheel (1) and ring gear (2) from pump housing
Installation:
- Insert pump wheel and ring gear with Vaseline in pump housing.
- When installed, markings on pump wheel and ring gear must be clearly visible.
- Lift out snap ring (1).
- Pry out shaft seal (2) with a screwdriver.
- Remove thrust washer (3).
Installation:
- Install thrust washer (3).
- Coat new shaft seal (2) with automatic-transmission oil.
- Drive in shaft seal with special tool 24 4 100.
- Press out seal and needle bearing with special tool 00 5 500 and 23 1 270 on hydraulic press.
Installation:
- Insert seal (1) in pump housing.
- Press in needle bearing (2) with special tool 24 1 010.
Continued in "Part 2 - Clutches (A/B/C)"