Part 1
Gear case and torque converter housingImportant
It is essential the greatest cleanliness is maintained when working with the transmission. Contamination can seriously affect the transmission's function and service life.
To dismantle
1. Drain the oil from the transmission in the car before starting removal. Remove the gearbox from the car. See removing gearbox assembly. Fit the dipstick pipe.
2. Plug the shaft holes. Use 87 92 665 Protective plug, drive shaft hole. Use plug 91 32 929 and seal 91 32 937 for the oil cooler hose connections and plug the bleeder pipe. Clean the outside of the transmission.
3. Remove the dipstick pipe.
4. Unplug the connector from the gear selector position sensor and speed sensor.
5. Fit 87 92 392 Holder, transmission to the transmission using M8x25 flange screws.
Note
Organize the workplace so that groups of associated parts that are dismantled can be kept together to facilitate refitting.
6. Mount the transmission on 78 74 878 Floor stand.
7. Bend out the lock washer for the gear position sensor nut and loosen the nut slightly.
8. Remove the speed sensors.
9. Remove the gear position sensor.
10. Insert 87 91 766 Gripping tool, torque converter into the torque converter. Remove 87 92 574 Holder. Remove the torque converter.
11. Turn the gearbox through 180 degrees in the stand.
12. Remove the bolts securing the valve body cover and knock loose the cover using a plastic mallet.
Important
Take care so as not to damage the sealing surfaces.
13. Disconnect the electrical connectors of the solenoids. Lift the casing of the system pressure solenoids (SLS, SLT and SLU) slightly with a small screwdriver to release the catch. Disconnect the oil temperature sensor.
14. Release the cable. Pull the cable and grommet out of the gear case. Place the holder to one side.
15. Remove the valve body bolts (only bolts with 10 mm head). Retain the small cover.
16. Unhook the manual valve connecting rod from the valve control and remove the valve body.
17. Remove the two seals.
18. Remove the bolts securing the oil pump to the gear case.
19. Pull off the oil pump and brake unit B2 from the gear case using 87 92 699 Puller (KM-993).
20. Remove the brake hub and freewheel F1.
21. Turn the gearbox through 90 degrees in the stand.
22. Remove the torque converter housing.
23. Knock loose the housing using a plastic mallet. Remove the seal.
24. Lift out the differential unit.
25. Remove the oil strainer and the cover plate.
26. Remove the oil channel plate from the gear case.
27. Remove the oil delivery pipe and holder.
28. Remove the torsion spring and the ratchet spindle for the hand brake.
29. Remove the hand brake control rod and the gear position disc. Release the detent spring.
30. Remove the holder for the hand brake control rod and the detent spring.
31. Remove the hand brake ratchet, guide pin and torsion spring.
32. Lift out the output shaft complete with thrust bearing and bearing race.
33. Lift out the C3 clutch and bearing race, and the planetary gear assembly. Retain the thrust bearing.
34. Lift out the B4 brake bands from the gear case.
35. Turn the gearbox through 180 degrees
36. Remove the bolts securing the end plate. Knock loose the cover with a plastic mallet. Remove the five seals.
37. Remove the circlip, cover, plunger, spring and the two O-rings for the B4 brake plunger. NB. Take care as the spring can thrust off the cover and plunger.
38. Remove the pipe holder and the pipe. Use 87 91 360 Puller.
39. Lift out the turbine shaft unit with clutches C1 and C2. Retain the thrust bearing and thrust bearing race.
40. Remove the bearing race from the turbine shaft unit and clutches C1 and C2.
41. Lift out the planetary gear sun gear and thrust bearing. Retain the bearing race.
42. Remove the rear ring gear. Retain the thrust bearing and bearing race.
43. Lift out the planetary gear unit with the large thrust bearing.
44. Remove the circlip for freewheel F2 and brake B3 using a screwdriver. Lift out the ring gear with F2 and B3 that contain the clutch discs, disc plates and flange.
45. Retain the thrust bearing and bearing race.
46. Remove the circlip for the spring unit using a screwdriver. Lift out the spring unit.
47. Carefully apply an air pressure of 4 bar through the oil passage for B3 to remove the B3 plunger as illustrated. Use a pair of blunt nose pliers if the plunger will not come out.
48. Turn the gearbox through 90 degrees.
49. Remove the circlip from the intermediate gear. Use 87 90 180 Pliers with 87 90 297 laws and a small screwdriver. Remove the intermediate gear.
50. Turn the gearbox through 90 degrees
51. Remove the drive shaft seal using a hammer and drift.
52. Fit 87 91 683 Puller - and 87 91 675 Puller and remove the bearing race from the gear case by heating the gear case with a heat gun for approx. 5 min. Pull out the bearing race and place the shim to one side.
53. If necessary, remove the brake band holder and the remaining plugs from the gear case. (Do not mix up the plugs.)
54. Remove the pipe holder and pipe from the end plate. Use 83 90 270 Sliding hammer and 87 92 384 Puller, torque converter seal.
55. If necessary, remove the accumulator for C1 from the end plate with spring and plunger.
56. Remove the oil sealing rings.
57. Remove the circlip and lift out the clutch assembly from the end plate.
58. Place the end plate in a hydraulic press. Position 87 91 535 Press ring and depress the spring assembly slightly so that the circlip can be removed. Use 87 90 180 Pliers. Lift out the spring assembly.
59. Apply an air pressure of approx. 4 bar to the hole and press our the piston from the end plate. If necessary, use needle nosed pliers to remove.
60. Remove all plugs from the end plate.
61. Remove the screw and pipe clamp from the torque converter housing.
62. Detach both ends of the pipe using 83 90 270 Sliding hammer and 87 92 384 Puller, torque converter seal. Remove the pipe. Be careful not to damage the pipe.
63. Remove the oil duct plate. Remove the three magnets.
64. Fit pullers 87 91 675 Puller and 87 91 683 Puller. Heat the bearing seat for about 5 minutes with a heat gun and remove the roller bearing.
65. Knock out the shaft seal.
66. Remove the bearing race of the conical roller bearing in the torque converter housing by heating around the bearing seat with a heat gun for about 5 minutes. Pull out the bearing using 87 91 683 Puller and 87 91 675 Puller. The bearing need only be removed if the torque converter housing or differential bearing is changed.
