Disassembly

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 affect operation or cause transmission breakdown. It is therefore extremely important that all transmission components are placed on a clean surface and then thoroughly cleaned before being reinstalled.





1. Plug all fluid and turbo pressure ducts.
2. Before dismantling the transmission, it should be carefully cleaned so that it is completely free of dirt.
3. Lift the transmission using tool No. 87 91 451, or equivalent.
- Place the transmission in a floor stand using fixture tool No. 87 91 469, or equivalent.
- Drain the transmission fluid.
4. Remove the tool securing the torque converter in position.
5. Pull out the torque converter using tool handles tool No. 89 91 766, or equivalent.

NOTE:
- Fluid runs out.
- Make sure that the shaft seal in the torque converter housing is not damaged.





6. Remove the five bearing cover screws and then remove the driver.
- Wrench size = 13 mm.
7. Turn the transmission one quarter turn so that the fluid filter cover is easily accessible.
- Undo the three fluid filter screws and remove the cover.
- There is a magnet in a recess in the cover.
8. Remove the filter insert using pliers.
9. Turn the transmission back up and withdraw the dipstick.
- Undo the valve body cover screws and remove the valve body cover and gaskets.
- Wrench size = 10 mm.





10. On models with turbocharger, remove the charge air pressure pipe using a sliding hammer, tool 87 91 360, or equivalent.

NOTE: Pipes and O-rings must not be reused.

11. On all models, undo the 10 screws (with larger head) from the valve body, remove the support bracket and lift off the valve body.
- Use TORX socket TX 27
12. Turn the transmission one quarter turn and undo the 18 screws securing the torque converter housing.
- Wrench size = 13 mm.
13. Lift off the torque converter housing with righthand drive shaft and speedometer drive.
- Remove the gasket.
14. Lift out the differential.





15. Remove the differential bearing race using puller tool No. 83 90 114, or equivalent.
16. Unscrew the pump complete with partition plate and brake C by undoing the 8 screws in the outer collar.
- Lift up the pump.
- Wrench size = TORX socket TX 27.
- Service oil pump as required.

NOTE: Leave the transmission in this position.

17. Remove shim holder and shim(s).
- Undo the brake band adjusting screw a couple of turns.
18. Lift out clutch A and clutch B with 2nd one-way clutch with turbine shaft.
- This is made easier if the shaft is turned slightly forwards and backwards.





19. Remove 2nd one-way clutch.
20. Remove clutch B from clutch A.
- In certain transmissions, there is a needle bearing between clutch A and clutch B.
21. Check that the bushing in clutch B is in the correct position.
- The bushing must not be located so that it blocks the fluid feed holes.
The bushing should protrude about 1.4 mm above the edge of clutch B.
22. Check the groove width between the seals and seal grooves.
- Measure using a feeler gauge.
- Clearance must not be greater than 0.17 mm.
23. Check the seal between clutch A and the partition plate cylinder.
a. Remove the seals from clutch A.
b. Place the seals in the partition plate cylinder where they normally seal.
c. Measure the clearance in seal seating.
- If clearance is greater than 0.50 mm, the seals should be changed.
- If this does not help, the partition plate cylinder must be changed.
d. Install the seals to clutch A.
24. Service clutch A and clutch B, refer to Overhaul.





25. Lift out the brake band by lifting opposite the brake band opening, making sure that the brake band is not bent outwards.
26. Lift off the engine shaft with clutch E, service clutch as required, refer to Overhaul.
27. Check the seal between clutch E and clutch A.
a. Remove the seal from clutch E.
b. Insert the seal in clutch A where it normally seals.
c. Measure the clearance in the seal seating.
- If clearance exceeds 0.50 mm, the seal should be changed.
- If this does not help, the turbine shaft must be changed.
d. Install the seal to clutch E.





28. Remove the entire intermediate shaft with both thrust washers and needle bearings.

NOTE:
^ When removing thrust bearings, the bearing washers may stick onto the corresponding bearing surface.
^ If this is the case, pick up the washer and place it on the shaft.

29. Remove the sun wheel shaft complete with thrust bearing, one bearing washer and a bearing holder.
30. Remove the drum with thrust bearing, one washer and one bearing holder.
31. Check if there is any wear to the drum teeth.
- The clearance between drum teeth and clutch B should not be greater than 0.15 mm, measured using a feeler gauge.
- If clearance is greater, the drum should be changed.
32. Lift off the sun wheel.
33. Remove the planet gear complete with thrust bearing, one washer and bearing holders.





34. Turn the transmission one quarter turn.
- In transmissions with a loose damper plate, this should be removed.
- Then undo the 13 remaining screws and remove the intermediate gear cover and gasket.
35. Engage the parking pawl using gear selector shaft setting tool No. 87 91 758, or equivalent, while pressing in the segment so that it does not jump out of position.

NOTE:
^ There are two designs of screw for the intermediate shaft.
^ One newer one with a flange and one older one without a flange.

- If the screws are of the older type without a flange, they are locked with Loctite and must be heated to 120° C using a hot air gun before they are removed.
- Otherwise, the screws will shear.
- If the screws are of the newer type, they have been locked by bending the flange.
- These bends must be pushed back before the screws are undone.
- When installing, the new type of screw with a flange should always be used.
- Wrench size = 36 mm.





36. Loosen both the intermediate shaft screws and undo them about two turns.

NOTE: Do not completely undo the screws.

37. Turn the transmission one quarter turn and disengage the parking pawl by setting the selector shaft to another position.
- Remove the screw securing the output shaft pinion.
- Remove the pinion from one side and the output shaft from the other.
- Removing output shaft bearings, refer to Overhaul.





38. Remove the planet carrier.
39. Completely unscrew the hexagonal screw.
- Remove the gear and shim from one side and the pinion shaft from the other.
- Remove pinion shaft bearing, refer to Replacement.





4O. Turn the transmission one quarter turn and extract the outer bearing race using puller tool No. 87 91 683, screwed into holder tool No. 87 91 667, or equivalents.
41. Remove the governor with governor flange.
42. Check the surface in the gear housing where the governor seals as well as the seals between the governor and the gear case.
a. Remove seals from governor.
b. Place seals in grooves in gear case where they normally seal.
c. Measure the clearance in seal seats.
- If clearance exceeds 0.50 mm, the seals should be changed.
- If this does not help, the gear case must be changed.
d. Install the seals to the governor.





43. Turn the transmission one quarter turn, fold back the locking tabs on the ring nut and remove the ring nut using wrench tool No. 87 91 550, or equivalent.
44. Remove the ring nut and tab washer.
45. The bearing race, together with the 1st one-way clutch and stop washer can now be pressed inwards in the gear case.

CAUTION: Do not remove the one-way clutch from the bearing race, or the parts of the one-way clutch will fall apart.

46. Turn the transmission one quarter turn.
47. Pry out the circlip for brake D using a suitable screwdriver.
48. Remove the entire plate assembly from brake D.
- Remove the Belleville washer.
49. Place a compressed air pistol against the fluid feed channel and push out plunger D using compressed air.
- Lift up the plunger with pliers.
50. Removing gear case, refer to Replacement.