Assembly

NOTE: Component identifier numbers used in the following illustrations relate to specific steps in the procedures below.

CAUTION: Automatic transmissions are extremely sensitive to contamination. The smallest amount of dirt can reduce performance and cause transmission breakdown. It is therefore extremely important that all components of the.transmission are placed on a clean surface and then carefully cleaned before being reinstalled.

NOTE:
^ After the gear case has been thoroughly cleaned, assembly can start as described below.
^ If the gearshift mechanism, parking pawl and kickdown cable have been removed, these parts should be reinstalled first, refer to Replacement.





Brake D
1. Install both O-rings to the plunger and lubricate them lightly using Vaseline.
- Then press the plunger into the housing, with the lip facing upwards.

NOTE: The plunger must be hard down, to avoid measurement error.

2. Install the Belleville washer and stop washer.
3. Install the entire plate assembly for brake D.
- Start with the spring plate and then install alternately an outer plate and a friction plate.
- Install the final plate and secure using circlip.

NOTE:
^ The spring plate is wavy.
^ The final plate is thicker than the other plates.
^ Brake D has 6 friction Plates.





4. Check and adjust clearance in brake D as follows:
a. Measure the thickness of the circlip. (selected thickness = 1.0 mm (O.039 inch)
b. Set up fixture tool No. 87 91 808 and dial gauge tool No. 78 40 622 with extended tip, or equivalents.
- Place the tip tool No. 87 91 857, or equivalent, on the final plate and set the dial gauge to "0".
c. Lift the entire plate assembly and read the clearance on the dial gauge.
- Clearance with the 6 plate pairs should be 2.0-2.5 mm (0.08-0.10 inch)
- If the actual reading deviates from the above values, a thicker or thinner circlip should be used.





1st One-Way Clutch
5. In order to facilitate installing, remove the plate assembly from brake D, leaving the Belleville washer in place.
- Install the washer and then install the complete 1st one-way clutch onto the splines in the gear case.
6. Make sure that the inner ring of the one-way clutch is not pressed out.
- Install the lock washer to the gear case.
- Thread on the wing nut and tighten using socket tool No. 87 91 550, or equivalent, to 50 Nm (37 ft. lbs.).

NOTE: Make sure that the lock washer is in the correct position so that it can be locked.

7. Check that the one-way clutch rotates freely in one direction, i.e. clockwise.
8. Turn the transmission one quarter turn.
9. Lock the circlip using a suitable drift.
10. Turn the transmission back one quarter turn.
11. Install the entire plate assembly for brake D.
- Start with the spring plate followed by alternately one outer plate and one friction plate.
- The friction plates should be thoroughly lubricated with automatic transmission fluid.
- Install the final plate and secure using circlip.

NOTE:
^ The spring plate is wavy.
^ The final plate is thicker than the other plates.





Planet Gear With Parts For Input And Output Drive Shaft
12. Install the drum to the 1st one-way clutch outer ring.
13. Install the output shaft with the annulus in the gear case.
- Install the gearwheel.
- Tighten the screw by hand.
14. Install the thrust washer, thrust needle bearing and the securing washer.
- Check the axial play in the planet gear drive as follows:
a. Axial play, short drive 0.20-0.70 mm.
b. Axial play, long drive 0.15-0.79 mm.
15. Install the planet gear in the gear case.
- Transmissions of early design have a loose thrust bearing.
16. Install the sun gear into the planet gear.
17. Install the drum onto the sun gear collar.





18. Install the thrust washer, thrust needle bearing and lipped washer into the drum.
19. Install the sun gear shaft and check operation.
- If correctly installed, the drum and the sun gear shaft should rotate in opposite directions.
20. Install the lipped washer, thrust needle bearing and thrust washer over the end of the intermediate shaft and install the intermediate shaft into position.
21. Install the two thrust washers and thrust needle bearing over the shaft journal on the intermediate shaft.





22. Lubricate the brake band with automatic transmission fluid and install it.
23. Install the engine shaft, turning it at the same time. If correctly installed, the shoulder of cylinder E should be flush with the edge of the plate holder on the sun gear shaft.
24. Depending on design, install the thrust washer or needle bearing and center it.

NOTE:
^ The thrust washer and needle bearing cannot be interchanged.
^ A needle bearing may only be used if the engine shaft is intended for this.

25. Install clutch A.
26. Check the distance between the turbine shaft and the engine shaft.
- If correctly installed, the distance should be about 21.6 mm (0.85 inch) with a plastic washer, or about 21.1 mm (0.83 inch) with a needle bearing.
27. Install clutch B. Turn back and forth so that the plates engage with each other and the clutch is in position.

NOTE: If correctly installed, the teeth of cylinder B should engage in the recesses in the drum until a gap of only about 1 mm can be seen between the drum for clutch A and clutch B.





28. Install the partition plate with brake C and the pump without the one-way clutch for 2nd gear.
29. Check axial play. the transmission should be assembled up to cylinder B.

NOTE: The 2nd one-way clutch should not be installed.

a. Place bronze shims (selected thickness 1.0 mm (0.039 inch)) and shim holder on the hub for cylinder B.
b. Insert the complete unit, pump/partition plate, while turning it forward and backwards until the Belleville washer for cylinder C is against the gear case.
- Then install the unit with two opposite screws.
- Tighten to: 10 Nm (7.3 ft. lbs.)
c. Attach measuring device tool No. 87 91 519, or equivalent, to the turbine shaft.
d. Check that the tip of the dial gauge is against the stator shaft and set the dial gauge to "O".
e. Measure axial play by raising the measuring device.
Correct axial play: 0.1-0.3 mm (0.0040-.012 inch)
f. If the actual value deviates from the correct value, a thicker or thinner shim should be selected.
- Lift off the complete unit, pump/partition plate.





30. Install shim holder and the measured shim in position on the hub of the partition plate.
- Always use bronze shims.
31. Install the 2nd one-way clutch into the friction plates for brake C' so that the inner teeth are in contact with the washers.
32. By turning the outer ring, check that all friction plates are engaged in the one-way clutch outer ring and that the friction plates rotate at the same time.
33. Slightly tighten the brake band adjusting screw so that cylinder B is fixed.
Turn the transmission one quarter turn.
34. Install the entire unit (pump, partition plate and 2nd one-way clutch) in the gear case by turning forwards and backwards and pressing in.

NOTE: Make sure that the one-way clutch does not drop out of the plate assembly.





35. If correctly installed, the Belleville washer should rest on the gear case and should deflect when the pump body is pressed.
36. Tighten the 8 partition plate screws.
- Wrench size = TORX socket-TX27
- Tighten to: 10 Nm (7.3 ft. lbs.)
37. Loosen the brake band and check axial play again, using measuring device.
38. Turn the gear case one quarter turn, apply grease (Vaseline) to the seals and carefully place the governor unit in the gear case.

NOTE:
^ Ensure that the sealing rings are not pinched.
^ If necessary, work them into the grooves with a blunt tool.
^ If the seals have been replaced with new ones, they should be allowed to rest for 30 minutes after having been installed to the regulator in order relax to their correct shape before the regulator unit is inserted into the rear case.





39. Turn the transmission one quarter turn and insert the pinion shaft by turning the drive gear on the governor flange, while holding the governor so that it does not drop out.
40. Install retaining tool No. 87 91 733, or equivalent, and turn the transmission one quarter turn.
41. Install the spacer sleeve over the pinion shaft in the governor unit.
42. Heat the gear case using a hot air gun for about 5 minutes and install the bearing race.
43. Before the washer is placed on the inner ring for the tapered roller bearing on the output shaft, the thickness of the washer must be checked.





44. Install shims (selected thickness = 1.90 mm (0.075 inch)) and drive to the pinion shaft and lightly tighten the screws.
45. Check preload on the output shaft as follows:
a. Press out the three dowels from the adjusting ring tool No. 87 91 741, or equivalent, using a suitable screwdriver or drift.
- Use a suitable support,
b. Place the adjusting ring with the tubular dowels facing upwards onto the inner race for the drive shaft's tapered roller bearing, e.g. the washer for the output shaft.
c. Install the drive.
d. Hold the segment depressed and engage the parking pawl by setting the selector lever to position "P" using adjusting wrench tool No. 87 91 758, or equivalent.

NOTE: If the segment is not pressed in, it may jump out of position.





e. Install the screw and tighten to a torque of 5 Nm (3.6 ft. lbs.) so that there is no play in the tapered roller bearings.
f. Release the parking pawl and turn the gearwheels through several revolutions.
- Retighten to 5 Nm (3.6 ft. lbs.) and turn.
- Repeat this until the screw is no longer turned when tightened.
- Wrench size = 36 mm.
g. Undo the screw, remove the gearwheel and use a micrometer to measure the predetermined shim thickness at the three dowels of the adjusting ring.
e.g.:
1: Dowel 6.34 mm (0.25 inch)
2: Dowel 6.34 mm (0.25 inch)
3: Dowel 6.33 mm (0.24 inch)
h. Calculate the average value of the three readings and select and install the appropriate shims. e.g. 6.32 mm (0.24 inch)
i. Insert selected shims.
46. Install the flange screw and lock it by bending the flange with a suitable drift.
- Tighten to: 150 Nm (110 ft. lbs.)

NOTE:
^ There are two designs of screw for the intermediate shaft, one new screw with a flange and on older screw without a flange.
^ When installing, the new type of screw, with a flange should always be used.





47. Check and adjust axial play in the pinion shaft.
- The transmission should be placed so that the intermediate gear drive points up.
a. Install preloading tool tool No. 87 91 733, or equivalent, for the pinion head on the transmission.
b. Install dial gauge with mounting.
c. Rotate the intermediate gear drive until a stable reading is achieved on the dial gauge. Then zero the gauge.
d. Back off the preloading tool screws several turns.
e. Rotate the intermediate gear drive until a stable reading is achieved.
f. The reading (X) is equivalent to axial play. Adjustment is made using shims as in next point.





g. Calculate shim thickness "S" using the following formula:
S: required shim thickness
X = reading of axial play
0.08 mm (0.003 inch) = selected play
S = 1.90 mm - X mm + 0.08 mm
Using American measurements, the formula becomes: O.O7 inch - X in + 0.003 inch
Example:
Measured axial play is 0.92 mm.
S = 1.90 - 0.92 mm + 0.08 mm = 1.06 mm
Required shim thickness "S" is 1.06 mm.
The selected shim 1.90 mm should be replaced with a 1.06 mm thick shim or the nearest possible.
h. If it proves necessary to install a shim which is not the same thickness as the original one, we recommend that the measurement should be repeated.
- Before measuring, the screw should be tightened.
- There is a long and a short design of screw.
- Tighten to:
24 mm long screw: 128-172 Nm (95-127 ft. lbs.)
70 mm long screw: 145-195 Nm (107-143 ft. lbs.)





48. Tighten the locking screw.
- Wrench size = 36 mm.
- Tighten to:
24 mm long screw: 150 Nm (110 ft. lbs.).
70 mm long screw: 170 Nm (124.7 ft. lbs.)

NOTE:
^ From transmission number 20426, a screw with a flange has been introduced.
^ This screw is locked by bending the flange using a suitable drift.
^ When installing, the new screw with a flange should always be used. There is a short and a long design of the screw.

49. Install the differential.
50. Install the torque converter housing seal.
51. Install the torque converter housing.
- Wrench size = 13 mm.
- Tighten to: 23 Nm (17 ft. lbs.)
52. Check and adjust differential preload as follows:





NOTE: For later setting of differential preload, the differential housing must be turned around over the side shaft (for the bearings to become seated).

a. Install the differential bearing race.
b. Screw on tool No. 87 91 279 and sleeve tool No. 83 90 114, or equivalents.
c. Tighten the tool screw to: 20 Nm (14. ft. lbs.).
- Turn the differential at least 25 times while tightening.
d. Undo the screw.
e. Measure depth and note reading.
f. Measure depth on bearing cover in the same way, note reading.
g. Calculate the difference between the two readings.
h. Add 0.1 mm (0.0039 inch).
i. Take a shim which corresponds to the reading, or one thicker if the exact measurement cannot be achieved.
j. Install shims, bearing cover and O-ring.
53. Install the intermediate gear cover with gasket and any damper plate.





54. Adjust brake band tightening torque.
a. Tighten the adjusting screw.
- Wrench size = 6 mm internal hexagon.
- Tighten to: 10 Nm (7.3 ft. lbs.).

NOTE: While tightening, cylinder B should be turned. Otherwise, there is a danger of the brake band becoming misaligned.

b. Mark the adjusting screw and housing and then undo the adjusting screw two turns (about 3 mm (0.12 inch).
c. Tighten the locknut to 50 Nm (37 ft. lbs.).
- Wrench size = 22 mm.





55. Set the segment to gear position 1.
- Use adjusting wrench tool.
56. Tighten the throttle cam with kick-down cable until the cam and throttle valve cannot be pinched.
57. Set the valve body selector slide to position 1 (fully in).





58. Install the valve body (kick-down cable withdrawn) and make sure that the selector slide engages with the pin in the lock washer.
59. Install the valve body.
- The screws are different lengths.
60. Do up all retaining screws in the valve body while installing the support plate.
- Wrench size = TORX socket - TX27
- Tighten to: 10 Nm (5.8 ft. lbs.)





61. Check the operation of the kick-down cable and shifting mechanism.
- Play in the kick-down cable should be 2-2.5 mm.
62. On models with turbocharger, install a new charge pressure pipe, complete with two new O-rings
- Use fixture tool No. 87 91 782, or equivalent.
- Use a plastic hammer to drive the pipe in as far as possible.

CAUTION:
^ If the pipe is so deformed that it does not exactly install the pattern of holes, the pipe should be thrown away.
^ Otherwise, there is a danger of the sharp edges on the pipe shaving off swarf from the holes.
^ This swarf will then destroy the transmission.

63. On all models, place the gasket on the edge around the valve body cover and install the cover.
64. Install the cover with four fixing plates and four hexagonal screws.
- Screw size = 10 mm (0.39 inch)
- Tighten to: 6 Nm (4.4 ft. lbs.)





65. Turn the transmission 180°.
- Install the filter insert with O-ring.
66. Place the O-ring on the cover and secure the magnet in position using grease (Vaseline).
67. Screw on the cover with three screws.
- Wrench size = TORX socket - TX27
- Tighten to: Nm (5.9 ft. lbs.)
68. Install the torque converter using the two gripping tools no. 87 91 766, or equivalent by turning it and pressing it fully in.
69. If the transmission is to be installed in the car.
- Secure the torque converter with locking tool No. 87 92 293, or equivalent.

NOTE:
^ If the transmission is to be dispatched for exchange, the torque converter should always be attached using a transit support.

70. Turn the transmission one half turn, install a new O-ring to the dipstick and place the dipstick in the valve body cover.

CAUTION:
^ After carrying out internal repairs on a transmission or changing to a new transmission, flushing equipment 87 91 824 should be connected to the transmission cooling system before starting the engine.
^ Otherwise, there is a danger of damage.