Intermittently No Engagement In Reverse

NOTE:
- Remedy A can be performed with transmission installed in vehicle.
- Remedy B requires transmission removal and rear cover disassembly.

Figure 1:

722.5 large intermediate plate. Optimal diameter of Bore 92 = 2.0 mm

Figure 2:

Upper side of 722.5 large intermediate plate (1) showing steel cover plate (2, shaded). Fastening screw (3) tightening torque: 4 Nm

A. CAUSE:
Extremely high Reverse engagement pressure leaking between Bore 92 of large intermediate plate and Drain valve KS (103) in transmission case due to:

- Graphite gasket material of original large intermediate plate becoming loose or of uneven tightness.
- Steel cover plate (2, Figure 2) on upper side of large intermediate plate gasket, not sealing properly.

A. REMEDY:
1. Replace large intermediate plate gasket.
2. Replace or retorque steel cover plate (2, Figure 2). Tightening torque: 4 Nm.

- Steel cover plate (2) is not flat, but is manufactured with a curve or bow to its facing surface.
- It is critical that the center of the steel cover plate curved arc contacts the gasket first, and is flattened as the fastening screw are tightened.

B. CAUSE:
- Pressure leakage at teflon seal rings for Clutch KS support flange and/ or intermediate shaft.
- Pressure leakage at Clutch KS.

B. REMEDY:
1. Perform remedy as listed in A. Remedy.
2. Replace all teflon seal rings on Clutch KS intermediate shaft.
3. Replace complete Clutch KS.

Refer to Parts Information listed below.

Part Information: