Part 2
NOTE: Procedure continued from Part 1. Part 185. Insert teflon rings (9) with grease. Ensure that the gap in rings (arrows) remains closed. If necessary, remove rings again and shape to a smaller diameter.
86. Insert front cover (10) with gasket, tighten bolts (18) to 13 Nm.
NOTE: The gasket may be used several times but must never be coated with sealing compound. In contrast, the combined bolts and washers (18) must be lightly coated with non-hardening sealing compound.
87. Rotate assembly device until output shaft (86) points upwards. Push snap ring (116) along output shaft as far as its groove.
88. Attach helical gear (78).
89. Insert axial retainer (43) in transmission housing.
90. Insert O-ring (48).
91. Insert centrifugal governor (50).
92. Swivel axial retainer (43) towards centrifugal governor (50) so that it engages in the groove in the governor shaft (arrow).
93. Insert cover (46) and attach circlip (47) with the aid of a screwdriver. Then pull cover outwards so that it contacts the circlip around its entire circumference.
94. Insert intermediate plate (21) and O-ring (22).
95. Attach secondary pump (20) and tighten hexagon socket bolts (45) to 8 Nm.
96. Check seating of axial bracket again, screw on nut (44) and tighten to 6 Nm.
97. Insert oil pipe (84) and tighten hexagon socket bolt (84a) to 8 Nm.
NOTE: Oil pipe (84) not used any more as of transmission no. 3 234 346.
98. Insert detent plate (82) with spring linkage and push in shaft (76).
99. Screw in hexagon socket bolt (82a) and tighten to 8 Nm.
100. Push roller (81) onto spring linkage (82).
101. Attach plastic guide (80) and push into locating bores.
102. Place shims (77) onto helical gear.
103. Push on parking lock pawl (74), insert expanding spring (75) and hook onto parking lock pawl (74).
104. Mount parking lock gear (73) with rotor or helical gear.
105. Measure axial play (C) of output shaft (clutch K2) and correct. Attach measuring sleeve (028) and tighten collared nut (82) to 100 Nm. Engage the parking lock pawl (arrow) to counter the nut. Attach seal (72). Position parallel-edged block (029). Measure depth from measuring sleeve (028) to block using depth gauge. Add 15 mm to the measured distance to obtain distance "b".
NOTE: The 15 mm is the height of the parallel-edged block (20 mm) minus the edge of the measuring sleeve (5 mm). Assemble rear cover.
Place parallel-edged block (029) on the sealing surface of rear cover. Measure from parallel-edged block (029) to the inside ring Of the ball bearing using a depth gauge. Subtract 20 mm from the measured distance to obtain distance "a". Distance "a" minus distance "b" equals the axial play "C". Correct the axial play "C" to 0.4 + 01 mm by adding or removing shims (77) below the parking lock gear (73) (see figure to item 102).
106. Push seal (arrow) onto oil pipe (102) for (mechanical) speedometer lubrication and insert oil pipe.
107. Mount rear cover (70), coat hexagon bolts (71) with non-hardening sealing compound and tighten to 13 Nm (8.8) or 28 Nm (10.9).
NOTE: The gasket may be used several times but must never be coated with sealing compound.
108. Insert washer (65).
109. Insert O-ring (63) into propeller flange (64).
110. Attach propeller flange (64), tighten double-hexagon collared nuts (62) to 120 Nm and lock in place with a suitable drift.
111. Screw in kickdown solenoid valve (61) and tighten to 20 Nm.
A 1st version up to 07/92
B 2nd version as of 08/92
112. Insert modulating pressure regulator valve (59) and pressure pin (59a).
113. Mount vacuum unit (60) with retaining plate (57) and tighten hexagon socket bolts (58) to 8 Nm.
114. Mount starter lockout switch (53), screw in hexagon bolts (55) but do not tighten.
37 Brake band plunger B1
38 Pressure pin
39 Lip seal
136 shims
137 O-ring
a Max. 6.5 mm
115. Insert lip sealing ring (39) at brake band plunger B1 (37) so that the sealing lip points towards the outside.
C26 Assembly device 201 589 03 59 00
031 Measuring device 126 589 06 21 00
116. Mount assembly device (026) and bolt on transmission housing.
117. Insert brake band plunger B1 with one pressure spring and measuring device (031).
118. Screw in spindle of assembly device (026) ensuring that pressure pin of brake band plunger B1 is inserted in brake band and that lip seal is not damaged.
NOTE: To adjust the clearance, it is sufficient for just one pressure spring to be installed.
119. Insert circlip (41), release assembly device (026) and remove.
NOTE: In order to be able to remove and install the circlip (41) without slackening the screw plug or transmission overload protection switch, a chamfer (arrow) must be cut on 1st version measuring devices.
031 Measuring device 126 589 06 21 00
120 Measure clearance "L" at brake band B1 and adjust.
NOTE: The thread on the measuring device (031) has 1 mm pitch, i.e. one revolution corresponds to 1 mm travel.
Screw in bolt on measuring device (031) by hand until resistance is delectable.
Using a torque wrench, screw in the bolt further, counting the revolutions, and tighten bolt to 1 Nm.
The idle travel at the brake band must be 1.8 - 2.0 mm, i.e. a torque of 1 Nm must be achieved after 1 8 - 2.0 revolutions.
37 Brake band plunger B1
38 Pressure pin
39 Lip seal
136 shims
137 O-ring
a Max. 6.5 mm
The clearance can be adjusted by inserting or removing shims (136) in the pressure pin (38).
025 Assembly device 201 589 03 59 00
121. Reattach assembly device and bolt in place. Install brake band plunger cover (40) and second compression spring in place of measuring device, then remove assembly device.
Brake Band Plunger B1 2nd Version With Automatic Adjuster As Of Transmission No.3 746 852
35/36 Return springs
37 Brake band plunger B1
37a Disc spring (modified as of transmission no. 3 931 462)
37b corrugated snap ring
37c Pin
38 Pressure pin
38a O-ring
39 Teflon ring (modified as of transmission no. 3 969 173)
40 Brake band plunger cover BV1
40a Locking device
Dismantling Brake Band Plunger
Remove brake band plunger from plunger cover. Spread locking device (40a) in brake bend plunger cover (40) using circlip pliers and remove pin (37c). Leave the locking device in the brake band plunger cover. Remove snap ring (illustration 3, item 37b) in brake band plunger using a screwdriver; then remove disk spring.
Assembling Brake Band Plunger
Insert pin (37c) in brake band plunger. Note installed position. Push disk spring (37a) over pin until it contacts the brake band plunger; note installed position. Insert snap ring (37b). Ensure that it is correctly seated. Press assembled brake band plunger into plunger cover until it locks in position audibly. Do not pull it apart by hand once it has locked. Install assembled brake band plunger; it adjusts itself automatically.
122. Insert pressure pin thrust bearing B2 (28) with larger diameter pointing towards brake band B2 (27).
123. Insert teflon ring (25) into groove with grease.
NOTE: Introduction of improved teflon ring (molded T-ring) as of transmission no. 3 915 083
124. Insert pressure pin (26)
NOTE: Pressure pins (26) are available in lengths of 47.2, 48.0, 48.8 and 49.6 mm for correcting the idle travel at brake band B2.
125. Introduce brake band plunger B2 (15) ensuring that pressure pin (26) engages in brake band.
Repair Note For Reconditioned Transmission
Phased in as of 06/94 the bore for supporting plunger B2 is reworked after wear limit is reached. This necessitates a modified sealing ring with a larger diameter for plunger B2. The housing is identified by engraving "89 dia.".
NOTES: Only the modified sealing rings may be installed when repairing reconditioned transmissions, the 1housings of which are identified with the diameter specifications (89).
126. Press in brake band plunger cover B2 (17) and insert circlip (23).
127. Measure clearance "L" at brake band B2 and adjust. Press brake band B2 (27) by the support tab towards the brake band plunger (in direction of arrow) so that brake band plunger rests against brake band plunger cover. Measure distance "a" at brake band using caliper gauge.
Similarly, press brake band B2 (27) by the support tab towards the thrust element (in direction of arrow). Measure distance "b". The difference between measurements "a" and "b" is equal to the clearance "L". Adjust clearance "L" to 5.5 - 5.7 mm by replacing the thrust pin (26) at brake band plunger B2.
128. Insert brake band guide B2, one-way valve (49), filler element (128), locating pin (135), temperature restrictor (117) and oil deflector (119) in transmission housing.
129. Assemble lower cover (13) with intermediate plate (14). Attach lower cover with intermediate plate ensuring that the oil Pipe (9) is inserted into the bore (arrow).
130. Center intermediate plate (14) with two bolts (7).
131. Insert bolts with washers (8) and tighten to 8 Nm.
132. Attach leaf spring (142) with bracket (141) and tighten bolt (140) to 8 Nm.
NOTE: Ensure that the locating pin for the brackets (141) is correctly inserted.
133. Mount range selector lever (52) so that the driver (54) is located in the range selector lever.
134. Insert hexagon bolt (51) and tighten to 8 Nm.
135. Move range selector lever (52) to position "N", insert a 4 mm cotter pin (arrow) through the range selector lever into the locating bore of the shift housing and tighten hexagon bolts (55) to 8 Nm. Then remove cotter pin.
136. Attach shift valve housing (A), ensuring that the range selector lever (A1) engages in the driver on the notched plate (arrow).
137. Insert bolts with washers (7) and tighten to 8 Nm. Note length of bolts. The three bolts marked with item no. 7a are only 50 mm, the remaining 12 bolts are 55 mm long.
138. Check play "a" between locking plunger (122) and stop on spring linkage (B2), and adjust if necessary. The play "a" is adjusted to 0.4 - 1.0 mm in position "N" by means of the plastic dip (118). The plastic clip is available in two thicknesses.
139. Check O-ring on control pressure cable and renew if necessary, then attach control pressure cable onto connecting rod (110). Insert limiting rod (111) into bore (arrow) and insert control pressure cable.
140. Turn control pressure cable until it locks in place.
141. Attach oil filter and tighten cross-head bolts to 4 Nm.
142. Attach oil pan (3) and tighten retaining bolts (4) to 8 Nm.
143. Remove bolt (arrow) and lift transmission out of assembly unit. After installation, check transmission for leaks and also check modulating pressure and adjust if necessary.