Part 1

NOTE: During assembly, provide bearing points and slide surfaces with specified ATF. Place new brake bands and lined discs of multiple plate brake for approx. 1 hour into ATF prior to installation.

NOTE Steps 1 - 58 are part of the dismantling procedure. Dismantling

59 Place housing (1) into assembly fixture and fasten with screw (arrow).
60 Screw-in closing plug with a new aluminum sealing ring and tighten to 10 Nm.
61 Insert guide ring (88a). then insert lip sealing ring (88) by means of self-made punch, sealing lip (arrow) should point in direction of brake band piston cover.

NOTE: As of transmission end no. 3 122 870 a onepiece brake band piston B2 will be installed (refer to item 145), previously two-piece. The one-piece brake band piston may be installed only together with a plastic piston guide ring (88a).





NOTE: The punch is self-made according to specified dimensions.





62 Place O-ring (91) into groove.
63 Insert radial sealing ring (92).
64 Screw-in closing plug (90) with new aluminum sealing ring and tighten to 10 Nm.





65 Place O-ring (arrow) into groove.





66 Provide grooves in supporting flange K 2 (79) with grease. Insert Teflon rings (115) and push into grooves to the extent that the gap (arrows) remains together.





67 Check thrust body B 2 for twist: Bore (arrow) and link should be aligned in one direction.

NOTE: As of transmission end no. 389 470, thrust body B 2 with ring groove to avoid failures caused by twisted thrust bodies.

NOTE: Thrust bearings B 2 brake band guide and brake band piston B 2 are installed in different versions. Below is a list of such versions.

Version "A"





Thrust bearing B2 together with brake band guide without oil drain bore (arrow). Installed up to transmission end no. 825 582.

Version "B"





Thrust bearing B2 with oil drain bore turned in downward direction (arrow) only in combination with brake band guide with additional oil drain bore (arrow). Installed starting transmission end no. 825 583.

Version "C"





Thrust bearing B2 with enlarged stroke, identification for elimination of ring groove (arrow) in combination with brake band piston B2 with ring groove (arrow) on spring retainer. Installed starting transmission end no. 909 459

NOTE: Install thrust bearing B2 with enlarged stroke only together with modified brake band piston B2. The previous thrust bearing can be combined with the old and the new brake band piston.





68 Insert thrust body B2 (29) with Strip (arrow) in upward direction.
69 Insert supporting flange (79) in accordance with hole pattern of fastening bore.

NOTE: Depending on version of outer plate carrier K2, supporting flanges of different design will be installed.





1st version "A"
Supporting flange K2 with lube bore (arrow) and spacing washer 0.5 mm (112) for outer plate carrier K2 with ball bearing. Installed from start of series.

2nd version "B"





Supporting flange K2 and thrust washer (113) with locating lug (1) and groove (2).
Installed
starting transmission end No. 51760 for M110
starting transmission end No. 80200 for OM617 ATL
starting transmission end No. 106276 for M116.

3rd version "C"
Supporting flange K2 without lube bore with thrust washer (113) and locating lug (3) inside. Installed starting transmission end No. 101853. Version "C" will he installed in vehicles with engine 117 starting transmission end No. 393445.





NOTE: Starting transmission end No. 53854 supporting flange K 2 3rd version (C) with thrust washer (113) 2nd version (B) is installed. Clutch K 2 is guided axially either by way of radial ball bearing (version "A") or a thrust washer (version "B"). For version "A", a steel washer (112) is placed on supporting flange (79), for version "B", a brass-coated thrust washer (113).





70 Screw in combination screws (114) and tighten to 11 Nm.





71 Insert steel or thrust washer. Insert thrust washer (113) in such a manner that the plate for torsion lock (arrow) is fixed in housing.

NOTE: Starting transmission end No. 101853 thrust washer (113) is located in supporting flange K2.





72 Check seat of teflon rings on supporting flange (79) once again.
73 Compress brake assembly B 2 (27) on supporting lugs as much as possible and insert in housing.

NOTE: A modified brake band B2 is installed starting transmission end No. 383608. The bore for the thrust pin (at thrust bearing end) is reduced by 1 mm. If the brake band is replaced on transmissions with lower end No., a new thrust pin part No. 126 277 51 75 must be used.





74 Place clutch K2 (70) on gear set.





75 Insert gear set into transmission housing while rotating input shaft (69).
76 Place transmission in vertical position with input shaft (69) in upward direction.





77 Check installation position of gear set. Gear set is correctly inserted, when the upper edge of the connecting carrier (arrow) is lower than the supporting surface of the outside plate LB 3.
78 Mount front cover on primary pump.
79 Insert damping spring (134), install starting transmission end No. 379225.

NOTE: For transmission of the previous version a damping spring can be installed in repair version part No. 126 993 03 15.





80 Assemble plates for multiple plate brake B 3 in sequence shown in illustration and insert individually.

NOTE: On vehicles with gasoline engine (Japan,USA) starting 1988 a spring retainer is mounted instead of compensating washer (5).





81 Measure B3 release clearance "L" = 1.5 - 2.0 mm and compensate.

Find dimension "d"
Place parallel bar (029) on machined surface and measure by means of depth gauge in direction of compensating washer (85).


Find dimension "e"





Place parallel bar (029) on piston of multiple-disk brake (12), measure by means of depth gauge in relation to gasket (19). The difference between the two dimensions provides the release clearance "L". Set release clearance "L" to its nominal value of 1.5-2.0 mm. Compensation is made by means of outside plates and compensating washers (85) of varying thickness.





82 Place axial bearing (94) into planetary carrier.
83 Provide groove in input shaft (89) with grease and insert grease pressure ring (95).





84 Connect assembly lock (arrow) to brake band B 1(30).





85 Rotate clutch K1 (83) to facilitate meshing of teeth.
86 Inset brake band B1 (30) in such a manner that pin of assembly lock (arrow) in Fig. item 84 is facing thrust body B1.
87 Install axial bearing (97).





88 Plug thrust pin (28) into thrust body B 1.
89 Renew O-rings (32).

NOTE: Thrust body with groove (arrow) is installed in transmissions with shift valve housing 2nd version. Except for transmission 722.308 where the thrust body with groove is installed already on shift valve housing 1st version.





90 Insert thrust body B 1 (31).





91 Screw in closing plug (33) and tighten to 70 Nm.





92 On transmissions with transmission overload protection screw in switch (S65) and tighten to 70 Nm.








93 Insert brake band guide (34) making sure that the locating lugs enter into bores in housing and push down until they are noticeably engaging.

Attention!
Starting transmission end No. 655 877 a brake band guide with a larger through-bore for brake, band piston is installed with removable thrust pin.





94 Measure end clearance "B" for clutch K 1 and compensate.
Rear housing not installed 0.8 - 1.2 mm.
Rear housing installed 0.3 - 0.5 mm.





Place gasket (19) on front cover (10). Place parallel bar (029) 126 589 04 31 00 on flange (arrow). Measure with depth gauge in relation to gasket (dimension "b").

Place parallel bar (029) on machined surface. Measure by means of depth gauge from parallel bar in relation to a roller of axial bearing (97) (dimension "a"). The difference between the two measurements is play "B". Adjust play by inserting pertinent shims (95) under thrust washer (96) of axial bearing (97) (refer to drawing item 94).





95 Check teflon rings on front cover and on input shaft for Correct seat.
96 Install front cover (10) with gasket, tighten fastening screws (18) to 13 Nm.

NOTE: Up to transmission end No. 313.790, close assembly thread bores with 2 short screws.





97 Turn assembly fixture in such a manner that output shaft (68) points in upward direction.
98 Slip circlip (116) up to its groove on output shaft (68).





99 Mount helical gear (78).





100 Install axial holder (43).





101 Insert O-ring (48).
102 Install centrifugal governor (50).





103 Swivel axial holder (43) in direction of centrifugal governor (50) in such a manner that it will enter groove of governor shaft





104 Mount cover (46).
105 Insert locking ring (47), then pull cover in outward direction to rest against locking ring with its entire circumference.





106 Insert intermediate plate (21).
107 Insert O-ring (22).





108 Mount secondary pump (20), tighten hex. socket screws (45) to 8 Nm.
109 Check seat of axial holder once again. Screw-on nut (44) and tighten to 6 Nm.





110 Insert oil pipe (arrow) tighten hex. socket screw (84) to 8 Nm.

Note: Procedure continues in Part 2. Part 2