Part 2
To assemble1. If changing the torque converter housing, transfer the outer plugs to the new housing. Carefully remove the old sealing compound from the sealing surface using a gasket scraper and wash the torque converter housing.
2. Heat the bearing seat with a heat gun and tap the roller bearing into the torque converter housing using 87 90 461 Sleeve, bearing ring and 83 90 189 Drift. Press in the bearing with the text facing downwards until it reaches the bottom of the torque converter housing. The side of the roller bearing forms the bearing race of the output shaft's thrust bearing. Remove the sealing ring before heating and fit a new ring once the bearing is in place.
3. Heat the bearing seat for the differential bearing race in the torque converter housing. Fit the bearing race. Make sure the bearing race is all the way home.
4. Fit the oil duct plate and the three magnets. Blow the pipe clean, apply Vaseline to the ends of the pipe and fit the pipe using a splinter-free plastic mallet. Take care not to bend or damage the pipe. Fit the pipe clip.
5. Heat the bearing seat for the differential bearing race in the gear case for about 5 min. Refit the shim and fit the bearing race. Make sure the bearing race is all the way home.
6. Lubricate the bearings with automatic transmission fluid.
7. Fit the differential and fit the torque converter housing. Only fit every other bolt. Fit a 87 92 483 Torque wrench and 87 91 337 Driver, measuring differential bearing torque to the differential housing (file down the key slightly if the tool does not fit the differential shaft). Turn until the reading is stable.
Important
Inspect the inside of the differential housing for damage. Check also the surfaces of the drive shafts.
Tightening torque 24 Nm (18 lbf ft)
Measure the prestress. Start value:
New bearing 1.0 Nm (7 lbf ft)
Refitted bearing 0.5 Nm (3.5 lbf ft)
8. If the prestress is not within specified limits, remove the differential and bearing race from the gear case and change shim. If the reading exceeds the specified value, change to a thinner shim. If the reading is lower than the specified value, change to a thicker shim. Shims are available between 1.0 - 1.90 mm in small intervals.
9. Remove the torque converter housing and lift out the differential.
10. Turn the gearbox through 90 degrees.
11. Fit new O-rings on the B4 brake plunger and plunger cover. Lubricate with petroleum jelly and fit the servo plunger with cover. Fit the circlip.
12. Put in place the intermediate gear assembly in the gear case.
13. Turn the gearbox through 90 degrees.
14. Use 87 90 180 Pliers with 87 90 297 laws to fit the circlip. Press the circlip into the groove with pliers.
15. Turn the gearbox through 90 degrees.
16. Apply petroleum jelly to two new O-rings for brake B3 and fit them on the brake plunger. Take care not to damage the O-rings. Press the plunger into the gear case.
17. Put in place the return spring unit on the plunger and fit the circlip in the groove on the gear case. Make sure the opening in the circlip is not aligned with the large recess. Use a screwdriver to make sure the entire circlip is in the groove.
18. Lay the bearing race and thrust bearing on the intermediate gear hub.
19. Fit the front ring gear and freewheel F1. Make sure the thrust bearing is positioned correctly and that the ring gear rotates freely anticlockwise and is locked clockwise.
20. Fit flanges, clutch discs and disc plates as illustrated.
21. Fit the circlip into the gear case. Check that the gap in the circlip is not aligned with the large notch.
22. Apply an air pressure of 4 bar in the oil passage as illustrated. Make sure the plunger moves easily.
23. Lubricate the thrust bearing for planetary gear P1 and P2 with Vaseline and fit the bearing to the front ring gear. Place the black side facing upwards.
24. Fit the planetary gear.
25. Place the thrust bearing race on the planetary gear lubricated with petroleum jelly.
26. Lubricate the thrust bearing for the planetary ring gear with petroleum jelly and place the bearing on the front of the planetary ring gear. Lay the planetary ring gear on the planetary gear.
27. Lubricate the bearing race with Vaseline. Position this on the planet ring gear.
28. Lubricate the bearing race for the planetary gear ring with petroleum jelly. Fit the bearing race.
29. Lubricate the thrust bearing with petroleum jelly and fit the sun gear shaft.
30. Fit the planetary gear sun gear unit into the planetary gear.
31. Lubricate the thrust bearing for the planetary gear sun gear with petroleum jelly and place the bearing on the sun gear. Make sure the bearing is fitted correctly with the black side face up.
32. center the clutch discs and plates using a screwdriver. Fit ring gear and clutch C1 as a complete unit. Turn the intermediate gear and C1 towards each other so that the planetary gear engages in the ring gear.
33. Make sure the ring gear and clutch C1 have fallen in place by measuring as illustrated. The distance must be approximately 51 mm.
34. If the bearing has been removed, remove the small sealing ring and heat the bearing housing in the end plate using a heat gun for approx. 2 min. and fit the roller bearing. The text on the side of the bearing should face down. Insert the sealing ring.
35. Fit the accumulator with spring and piston to the end plate.
36. Blow the pipe clean, apply Vaseline to the ends of the pipe and fit the oil pipe to the end plate. Make sure the O-rings are seated correctly on the pipe. Take care not to deform or damage the pipe. Use a splinter-free plastic mallet.
37. Place the clips on the pipe and tighten the screws.
Tightening torque 5.5 Nm (4 lbf ft)
38. Fit the seals to the bearing housing.
39. Lubricate the O-rings with Vaseline and fit the piston for brake B5 in the bottom of the end plate.
40. Place the end plate in a hydraulic press and carefully depress the spring assembly sufficiently so that the circlip snaps into place. Use 87 91 543 Press ring and 87 90 180 Pliers with 87 90 297 laws.
41. Fit the plates for brake B3. Place the spring washer at the bottom with the concave side facing up.
42. Fit the oil pipe and clip to the gear case. Take care not to deform or damage the pipe. Use a splinter-free plastic mallet.
43. Fit the bearing race for the rear cover into the end plate. Lubricate the bearing race with Vaseline. Lay the bearing race and the thrust bearing in the C1/C2 unit.
44. Clean the sealing services with Cleaning agent, Loctite Super Clean 7063. Keep the sealing services free from grease.
45. Apply an approx. 1 mm thick bead of 87 81 841 Silicone flange sealant to the end plate.
46. Lubricate five new sealing rings for the oil holes with Vaseline and fit them to the gear case.
47. Fit the end plate onto the gear case. Apply Thread locking adhesive, Loctite 577 to the bolts and tighten alternately. (Different lengths)
Tightening torque 25 Nm (18 lbf ft)
48. Turn the gearbox through 180 degrees.
49. Align the teeth on the plates for brake B5 using a screwdriver.
50. Check that the two plastic washers are correctly positioned. Then fit planetary gear P4 and the ring gear with thrust bearing as a unit into brake B5.
51. Lubricate the O-ring for the hold-down bolt with petroleum jelly and tighten it.
Tightening torque 140 Nm (104 lbf ft)
52. Oil in the brake band for brake B4 with automatic transmission fluid. Fit the brake band and the anchor bolt pin in the brake band recess.
53. Insert the thrust bearing.
54. Fit clutch C3 into the gear case. Lift the brake band slightly to facilitate fitting.
55. Align the teeth of the C3 clutch using a small screwdriver.
56. Fit the sealing rings to the output shaft. Lubricate the sealing rings with Vaseline.
57. Align the plates using a screwdriver and fit the output shaft complete with clutch unit C3. Make sure that the shaft falls into place at the same height as the intermediate gear. Check that the shaft and gear rotate freely. Fit a bolt to the shaft to rotate it.
58. Fit the thrust bearing race and the thrust bearing on the output shaft unit.
59. Fit the spring and bolt. Place the ratchet on the correct side of the spring.
Tightening torque 5.5 Nm (4 lbf ft)
60. Fit the guide pin in the hole.
61. Position the guide fork and the ratchet axle and spring.
62. Fit the ratchet sector gear position spring. (Note the different bolt lengths.)
Tightening torque 5.5 Nm (4 lbf ft)
63. Press in a new seal into the gear case. Lubricate the lips of the oil seal with automatic transmission fluid.
64. Fit together the control rod and the ratchet sector and slacken the spring. Make sure the hand brake detent falls into position and is in working order. Put the selector lever in neutral.
65. Blow the pipe clean, apply Vaseline to the ends of the pipe and fit the oil pipe and clip. Take care not to deform the pipe. Use a splinter-free plastic mallet.
66. Fit the oil duct plate to the gear case (short bolts). Tighten the bolts.
Tightening torque 5.5 Nm (4 lbf ft)
67. Fit the cover with two bolts.
Tightening torque 5.5 Nm (4 lbf ft)
68. Fit a new oil strainer and tighten the bolts. Make sure the seals are positioned correctly, one on each side.
Tightening torque 5.5 Nm (4 lbf ft)
69. Fit the differential housing unit.
Important
Inspect the inside of the differential housing for damage. Check also the surfaces of the drive shafts.
70. Clean the sealing surfaces on the gear case and the torque converter shell. Use Cleaning agent, Loctite Super Clean 7063. Keep surfaces free from grease.
71. Fit a new seal into the gear case and apply an approx. 1 mm thick bead of 87 81 841 Silicone flange sealant to the gear case as illustrated. Fit the torque converter housing.
72. Apply Thread locking adhesive, Loctite 577 to the inside bolts. Fit the bolts (different lengths). Tighten the bolts.
Tightening torque 25 Nm (18 lbf ft)
73. Clean the magnetic surface on the drain plug and fit it with a new gasket.
Tightening torque 40 Nm (30 lbf ft)
74. Turn the gear case so that the shaft points approx. 45 degrees downward.
75. Apply Vaseline to the O-ring for the oil pump unit. Align the plates using a small screwdriver. Insert the thrust washer greased with Vaseline into brake B1.
76. Fit freewheel F1 and the bearing race for brake B1 and B2 to the oil pump unit. Lubricate the thrust washer for F1 with Vaseline and fit it.
77. Place the oil pump unit so its bolt holes are aligned with those in the gear case. Press the pump unit in place carefully. Tighten the bolts carefully and alternately.
Tightening torque 25 Nm (19 lbf ft)
78. Turn back the gear case 45 degrees
79. Check that the turbine shaft has an end play of 0.37 - 0.9 mm. Use 78 40 622 Dial gauge and 87 90 727 Bracket, dial gauge.
80. Fit the two sealing rings.
81. Connect the manual valve connecting rod to the manual valve control on the valve body unit. Screw in the bolts loosely. Take care not to fold the gasket.
82. Fit the gasket on the cover, fit the cover bolts. Tighten all the valve body bolts alternately.
Tightening torque 10 Nm (7 lbf ft)
83. Apply petroleum jelly to a new O-ring and fit it together with the cable grommet and the wiring harness for the solenoids on the gear case.
84. Plug in the connectors for the eight solenoids and fit the oil temperature sensor.
85. Clean inside the valve housing. Remove any gasket remains on the contact services between the cover and the gear case. Clean the sealing surfaces with Cleaning agent, Loctite Super Clean 7063.
86. Apply a bead of 87 81 841 Silicone flange sealant about 1 mm thick to the cover and fit the cover to the gear case. Apply Thread locking adhesive, Loctite 577 to the bolts (different lengths) and tighten the bolts alternately.
Tightening torque 25 Nm (19 lbf ft)
87. Turn the gearbox 180 degrees
88. Fit new O-rings to the speed sensors. Clean the speed sensors and make sure that there is no swarf on the magnets. Grease the O-rings with Vaseline and apply thread sealant to the bolts. Fit the two speed sensors. Tighten the bolts.
Tightening torque 5.5 Nm (4 lbf ft)
89. Fit the gear selector position sensor. Fit the holder for the cable grommet. Tighten the bolts on the gear selector position sensor first (important). Then tighten the nut on the gear selector position sensor and bend up the lock washer.
Tightening torque 8 Nm (6 lbf ft)
90. Engage neutral and fit 87 92 467 Adjustment tool, gear selector position sensor. Undo the bolts for the gear selector position sensor and adjust it so that the line is visible in the center of the groove in the setting tool. Tighten the bolts.
Tightening torque 25 Nm (18 lbf ft)
91. Remove the adjustment tool.
92. Change the torque converter seal, see adjustment/replacement Torque converter seal.
93. Fit the torque converter. Use 87 91 766 Gripping tool, torque converter Fit 87 92 574 Holder.
94. Make sure the torque converter has been fitted in the correct position and lay a steel rule on the mating face of the torque converter. Measure the distance between the mating face and the drive plate contact surface on the torque converter. The distance must be at least 15 mm.
95. Remove 87 91 766 Gripping tool, torque converter.
96. Fit new drive shaft seals. Use 83 90 122 Drift.
97. Remove the gearbox from the stand. Remove the holder from the gearbox.
98. Plug in the connectors to the gear selector and speed sensors.
99. pry off the type plate from the changed case using a screwdriver.
100. Straighten the plate with a hammer. Widen the hole with a tapered drift and an M10 nut for support. Lay the plate on the new gear case and press it on. Use an M8 nut for support over the center pin and seal with a hammer.
101. Fit the gearbox in the car. See To fit, Complete automatic transmission. Remember to clean the oil cooler with 87 91 824 Flushing equipment.