Transmission, Assembling

Transmission, assembling
After replacing planet carrier, adjust. Adjustments





- Install O-ring in planet carrier.





- Insert axial needle bearing with washers in input gear.
1. Input gear is installed in transmission housing.
2. Axial needle bearing washer, insert smooth side into input gear.
3. Axial needle bearing
4. Axial needle bearing washer
5. Install planet carrier with seal





- Insert small sun gear with washer and axial needle bearing into planet carrier.
1. Axial needle bearing
2. Axial needle bearing washer
3. Small sun gear can only be removed from planet carrier on transmission "DFG"
4. Planet carrier
- Center washer and axial needle bearing in small sun gear.
- Insert inner and outer -B1- plates.
- Insert pressure plate with flat side facing plates.
Thickness of pressure plate varies according to number of plates.





- Insert dished washer with convex facing toward one-way clutch.
When replacing
^ Transmission housing
^ One-way clutch
^ Piston for reverse gear brake -B 1-
^ or plates
then adjust -B1-. Adjustments





- Preload one-way clutch rollers with assembly ring 3267 and insert one-way clutch.





Note: Installation position of one-way clutch Retaining wedge (arrow) must be seated in machined groove on transmission housing.
- Install circlip for one-way clutch -b-.
- Insert circlip gaps over one-way clutch retaining wedge (arrow).





- Insert baffle block -2- in transmission housing groove, at ATF breather hole-1-





- Install circlip for supporting tube -a-.
- Install circlip gaps over one-way clutch retaining wedge (arrow).
- Perform -B1- measurement check. Clutch
- Install Transmission Vehicle Speed Sensor (VSS) -G38-.





- Install components in transmission housing starting with large sun gear down to small input shaft.
1. Large sun gear
2. Needle bearing washer (collar faces to large sun gear)
3. Axial needle bearing
4. Large input shaft
5. Axial needle bearing
6. Needle bearing
7. Small input shaft





- Install small drive shaft bolt -1- with washer -2- and shim -3-, Tightening torque 30 Nm (22 ft. lbs.).
^ Insert shim -3- on small drive shaft shoulder (arrow).
^ Determining shim thickness; refer to Planetary Gears; Adjustments.
- Perform planet carrier measurement check.





- Install axial needle bearing with washer on 3rd and 4th gear clutch -K3-.
1. Axial needle bearing with thrust washer
- Moisten axial needle bearing washer with ATF so that the bearing, when installing sticks to -K3-. Insert bearing washer on -K3-.
2. 3rd and 4th gear clutch -K3-





- Ensure piston rings seat correctly on -K3-.
- Ensure piston ring ends are connected.





- Insert 3rd and 4th gear clutch -K3-.
- Install seal -1- in groove (arrow).





- Insert 1st to 3rd gear clutch -K1-.





- Insert shims -arrow- in -K1-.
^ Remeasure shim when replacing -K1-, -K2- or ATF pump; refer to Clutch; Adjustments.
^ 1 or 2 shims can be installed.





- Insert reverse gear clutch -K2-.
- Insert supporting tube for -B2- plate set (arrow) so supporting tube groove engages in free gear wedge.





- Install -B2- plates as follows:
- Insert a 3 mm thick outer plate
- Insert three spring caps in outer plate
- Insert compression springs (arrows)
- Insert all, but the last outer plate
- Insert three spring caps onto compression springs.
Only on transmissions with corrugated spring washer is brake clearance -B2- determined by the last outer plate thickness. Determining plate thickness.
- Insert last -measured- outer plate.
- Install corrugated washer





On all other transmissions (with retaining ring -b-) the last outer plate is always 3 mm thick. The clearance of brake -B2- is determined by shim -a-, on which retaining ring -b- seats. A corrugated spring washer is not present.
- Insert last outer plate -3 mm thick-.
Determine shim.
- Install shim.
- Insert retaining ring -b- on shim. Smooth side facing shim.
When replacing
^ Transmission housing
^ Supporting tube
^ ATF pump
^ Spring washer
^ Retaining ring
^ or the plates
2nd and 4th gear brakes -B2- are to be adjusted. Clutch
Component part application according to transmission code letters.
- Install ATF pump seal.
- Install ATF pump O-ring.





- Install ATF pump.
- Tighten bolts even and diagonally.
Ensure O-ring is not damaged.
Tightening torque: 8 Nm (71 inch lbs.) then turn an additional 90°.
Additional turns can be done in several stages.
- Perform clutch play measurement check. Clutch





- Drive in cover with sleeve 40-20.





- Insert sealing plugs with O-rings.
Installation position: Lug -arrow- engages in oil channel.
- Install valve body with conductor strip.
- Install oil pump.
- Install torque converter.
- Install transmission.
- Fill with 3 liters (3.17 qt.) ATF then check ATF level and top-up.