Part 1

Control pressure cable (98)
Slacken, remove and attach locking device with screwdriver (item 1)
Transmission (1)
Clamp on assembly trestle 116 589 06 59 00 and mounting plate 126 589 10 63 00 (item 2).
Oil pan (3)
Remove, install, Hexagon bolts 8 Nm (item 3).
Oil fitter (5)
Remove, install, Cross-head bolts 4 Nm (item 4).
Shift valve housing (A)
Remove, install, 8 Nm, note different length of bolts (item 5).
Leaf spring (142) and bracket (141)
Remove and install with hexagon bolt (140), 8 Nm (item 6).
Lower cover (13) with intermediate plate (14) and oil pipe (9)
Remove, install. Bolts with washers (8), 8 Nm. Raise complete unit and dismantle lower cover. Check clearance between shut-off plunger and stop for spring linkage (0.4 - 1.0 mm) (item 7).
One-way valve (49), brake band guide B2 (101), locating pin (135), oil deflector (119), temperature throttle (117)
Remove, install (item 8).
Filer piece (128)
If fitted, check that it is secure.
Brake band plunger cover B2 (17)
Remove by extracting circlip (23) (item 9).
Brake band plunger B2 (15)
Remove, install. When installing. adjust clearance "L" with thrust pin (26) 5.5-6 mm (item 127).
Brake band plunger B1 (37)
Remove and install with assembly device 201 589 03 59 00. Remove circlip (41), cover (40) and return springs (35, 36). When installing, adjust clearance "L" to 1.8 - 2.4 mm as described in items 118 to 124. Check measuring device 126 589 00 21 00, lip sealing ring (39) (items 12 - 15).
Brake band guide B1 (34)
Remove, install (item 16).
Thrust element of thrust bearing B1 (31)
Remove, install; unscrew, screw on screw plug (33) or transmission overload protection switch (330), 70 Nm. Replace O-rings (32) (item 17).





Range selector lever (52)
Pull off by unscrewing hexagon bolt (51), 8 Nm (item 19),
Starter lockout switch (53)
Remove by unscrewing bolts (55), 8 Nm. Locate when installing (see item 20).
Vacuum unit (60)
Remove and install with retaining plate, 8 Nm. Remove and insert modulating pressure control valve (59) and heat expansion pin (59a) (items 21, 22).
Kickdown solenoid valve (61)
Unscrew, screw on, 20 Nm (items 23, 111).
Joint flange (64), or internally-geared wheel (64a)
Remove, install. Slacken twelve-point collared nut (62 or 120 Nm, lock (items 24, 110). Wrench socket 126 589 02 09 00.
Washer (65)
Remove (item 25).
Rear transmission cover (70) or adapter housing (70a)
Unscrew, screw on hexagon bolts (71), 13 Nm (8.8). or 28 Nm (12.9). Then remove cover by tapping gently with a hammer and dismantle. Check seal (items 26, 27, 107).
With electronic speedometer, parking lock gear (73) with rotor, parking lock paw (74) and spring (75)
Remove install (items 29, 103, 104).
Oil pipe (102) for mechanical speedometer drive
Disconnect, connect (item 30).
Parking lock gear (73), parking lock pawl (74) and spring (75)
Remove, install (items 30. 103. 104).
Shim (77)
Determine thickness by measuring axial play of output shaft (item 105).
Attachment - 126 589 04 31 00
Measuring sleeve - 126 589 06 14 00
Plastic guide (80) and roller (81)
Pull off, push on (items 31, 100 and 101).
Spring linkage with notched plate (82)
Unscrew, screw in hexagon socket bolt (82a). then pull out shaft (76) and remove notched plate (item 32).
Oil pipe (84)
Remove, install. 8 Nm (items 33. 97).
Secondary pump (20)
Remove, install. Nut (44) 6 Nm, allen bolts (45) 8 Nm, (items 35 96). Remove O-ring (22) and intermediate plate (21) (items 36 94).
Centrifugal governor (50)
Pull out after removing circlip (47) and cover (46), insert. To do this, the axial retainer (43) must be swivelled back (items 37 - 38, 90 - 92).
Axial retainer (43), helical gear (78) and snap ring (116)
Remove, install (items 39 - 41, 88, 89).





Front transmission cover (10)
Remove, install complete. Bolts with washers (18) 13 Nm, dismantle, note location of teflon rings. Before installation, measure axial dearance "B" for dutch K1 and adjust. 0.4-0.6 mm (see item 83). Then insert shim (95), friction ring (96) and axial bearing into dutch K1.
Gear set (69)
Remove complete. When installing, adjust clearance "L" = 1.5-2.0 mm of multiple-disc clutch B3 (item 76). Insert discs (133) and belleville spring (85) (item 44).
Brake band B1 (30) and dutch K1
Remove and install with gear set (see items 45, 78).
Damping spring (134)
Remove, install (item 47, 74).
Thrust pin (28)
Remove, install (item 48, 125).
Clutch K2 (100)
Pull out, when installing, push onto gear set and push in with gear set (items 49, 69).
Brake band 132 (27)
Remove, install by compressing brake band as much as possible (68) (items 50, 68).
Support disc (113)
Remove, install (item 66).
Thrust element B2 (29)
Pull out, check and insert with tab upwards (items 51, 64).
Support flange (79)
Remove, install. Bolts (114) 11 Nm. Stick teflon rings (115) into groove with grease (items 54, 60 - 62).
Guide ring (88a) and lip sealing ring (88)
Check and replace if necessary. Drift is shop-made tool (item 56).
O-rings (91, 92), sealing rings (92) and aluminium sealing rings (90)
Check and replace if necessary (items 57 - 59).


Dismantling





1. Remove control pressure cable. Release locking device using a screwdriver (arrow) and detach control pressure cable.





2. Bolt mounting frame to assembly jig. Position transmission in the mounting frame and secure in place with the bolt (arrow).





3. Unscrew bolts with washers (4) and remove oil pan (3).

Installation Note
Tightening torque 8 Nm.





4. Unscrew cross-head bolts (6) and remove oil filter (5).

Installation Note
Tightening torque 4 Nm.





5. Unscrew bolts (7/7a) and remove shift valve body, (A).

Installation Note
Tightening torque 8 Nm. Note different lengths of bolts.





6. Unscrew, hexagon bolts (140). Remove bracket (141) with leaf spring (142).

Installation Note
Tightening torque 8 Nm.

7. Unscrew bolts with washers and lift off lower cover (13) with intermediate plate (14) and oil pipe (9). Dismantle lower cover.

Installation Note
Tightening torque 8 Nm.





8. Remove one-way valve (49), brake band guide B2 (101), locating pin (135), temperature throttle (117) and oil deflector (119). Check that filler element (128) is correctly seated.

NOTE: As of 08/90. the filler element (128) is no longer featured in several models of transmission.





9. Push in brake band plunger cover B2 (17) and remove circlip (23).
10. Remove brake band plunger cover.





11. Pull out brake band plunger B2 (15) with thrust pin (26) clipped in.

Installation Note
Adjust clearance "L" to 5.5 - 5.7 mm with thrust Pin (26) (Item 127).

NOTE: Procedure continued in part 2. Part 2