Disassembling Transmission

Disassembling and Assembling Transmission

Preceding work:
Removing and installing transmission with torque converter. Remove and Installing Transmission With Torque Converter







Control pressure cable (98)
Loosen lock with screwdriver. Detach and attach.

Transmission (1)
Clamp onto assembly pedestal 116 589 06 59 00 and mounting plate 126 589 10 63 00

Oil sump (3)
Remove, install. Hexagon bolts 8 Nm

Oil filter (5)
Remove, install. Bolts 4 Nm

Control valve body (A)
Remove, install, 8 Nm. Pay attention to different bolt lengths.

Detent spring (142) and bracket (141)
Attach and fit on with bolt (140), 8 Nm.

Bottom cover with intermediate plate (14) and oil pipe (9)
Remove, install. Bolts (8) 8 Nm. Lift off complete. When assembling, check stop of resilient linkage (0.4-1.0 mm).

One-way valve (49), brake band guide B2 (101), locating pin (135), oil defector piece (119), temperature inductor (117)
Remove, insert.

Brake band piston B2 (15)
Remove and take off retaining ring (23) When installing, set play "L" of 5.5 - 6 mm with thrust pin.

Brake band piston B1 (37)
Remove and install with assembly device 201 589 03 59 00. Take off retaining ring (41), cover (40) and return springs (35, 36). When installing, set play "L" of 1.8-2.4 mm. Measuring device 126 589 06 21 00 check lip seal (39).

Brake band guide B1 (34)
Remove, install.

Thrust body B1 (31)
Remove, install by unscrewing, screwing on screw plug (33) or transmission overload protection switch (33b), 70 Nm. Check O-rings.

Starter lock-out switch (53)
Take off by unscrewing bolts (55), 8 Nm. When installing, fix in place.

Vacuum unit (60)
Detach and fit on with retaining plate (57),8 Nm. Remove modulating pressure control valve (59) and thrust pin (59a), and insert.






Kick-down solenoid valve (61)
Unscrew, screw on, 20 Nm.

Joint flange (64)
Remove and install by loosening twelve-side collar nut. 120 Nm, and lock. Wrench socket 126 589 02 09 00.

Washer (65)
Remove.

Rear transmission cover (70)
Unscrew and screw on hexagon bolts (71), 13 Nm. Detach cover by means of light hammer blows, lift off and disassemble.

Oil pipe (102) for mechanical speedometer drive.
Take off, fit on.

Parking lock gear (73), parking lock ratchet (74) and spreader spring (75)
Take off, fit on.

Shims (77)
Calculate thicknesses by measuring end play of output shaft.

Plastic guide (80) and roller (81)
Remove, fit on.

Resilient linkage with detent plate (82)
Unscrew and screw in hexagon socket bolt (82a), then pull out shaft (76) and remove detent plate (82).

Snap ring (123), helical gear (78) and retaining ring (116)
Detach, attach.

Secondary pump (20)
Remove, install. hexagon socket bolts (45), 8 Nm. Take off O-ring (22) and intermediate plate (21).

Retaining ring (47), cover (46)
Take off.

Retaining ring (43)
Together with pliers 201 589 00 37 00 and pull out centrifugal governor, insert.






Front transmission cover (10)
Remove install by unscrewing, screwing in bolts (18), 13 Nm, pay attention to Teflon rings. Before installing, measure end play "B" for clutch K1 and set to 0.6 - 1.0 mm. Next, insert shim (95), thrust washer (96) and axial bearing into clutch K1.

Gear set (86-87)
Remove complete. When installing, set play "L" of multi-disc brake B3 to 1.5 - 2.0 mm. Do this by inserting discs (104, 105) and Belleville spring washer (85).

Brake band B1 (30) and clutch K1 (83)
Remove and install with gear set.

Damping spring (134)
Remove, insert.

Thrust pin (28)
Remove, instal: and adjust.

Clutch K2 (100)
Pull out, when installing fit onto gear set and push in together with gear set.

Thrust washer (113)
Remove, insert.

Supporting flange (79)
Remove1 install. Hexagon bolts (114), 11 Nm. Stick Teflon rings (115) into the groove with grease.

Brake band B2 (27)
Remove and install by compressing brake band as far as possible.

Thrust body B2 (29)
Pull out and check, and insert with tab facing upwards.

Guide ring (88a) and lip seal (88)
Check, replace if necessary. Produce shop-made mandrel.

O-rings (91), radial seals (92) and aluminum seal (90)
Check, replace if necessary.

Adjustment Data:

Lubricants:

Shop-Made Tool:

Tightening Torque In Nm.:

Dimensions:

Sequence Of Discs LB3 Up To 08/88:

Sequence Of Discs LB3 Up To 08/88:

Sequence Of Disc LB3 From 09/88:

Disc Versions:

Special Tools

Special Tools:

Note:
When performing assembly work, the sealing surface of the cast oil distributor plate in the transmission housing must be treated with care. Furthermore, scrupulous cleanliness must be ensured. The transmission's correct operation depends on there not being any dirt on the transmission parts and in the oil circuit. For this reason, after disassembling, remove the gasket residues, wash all the parts thoroughly, flush through oil passages and blow out with compressed air.

Rubber gaskets must not come into contact with washing petroleum as this may attack the rubber. Use metnylated spirits to clean rubber parts.

Ensure also that the parts do not come into contact with fluffy rags, as fluff sticking to the parts can cause operating faults.


Disassembly






1. Transmission without selector program:
Remove control pressure cable by pressing tab (arrow) towards the sleeve (111), turning 90° counter-clockwise and pulling upwards. Detach connecting rod.






2. Transmission with selector program:
Use a screwdriver (arrow) to release lock.






3. Transmission with selector program and shift point retard:
Loosen screw and turn locking tab (arrow).






4. Bolt mounting plate (071) to assembly pedestal (070). Insert transmission into mounting plate and fix with bolt (arrow).


Note:
If stiffener rib is touching the recess of the retaining pin, rework retaining pin slightly.

070 Assembly pedestal 116 589 06 59 00

071 Mounting plate 126 589 10 63 00






5. Unscrew hexagon bolts (4) and take off oil sump (3).






6. Remove screws (6) and take off oil filter (5).






7. Remove screws (7) and take off control valve body (A).
Disassemble and assemble control valve body.


8. Unscrew hexagon bolts (140). Take off bracket (141) together with detent spring (142).






9. Unscrew bolts, lift off bottom cover (13) together with intermediate plate (14) and oil pipe (9). Disassemble bottom cover.






10. Remove one way valve (49), brake band guide B2 (101), locating pin (135), temperature restrictor (117) and oil defector piece (119).






11. Press in brake band piston cover B2 (17) and remove retaining ring (23), take off brake band piston cover.






12. Pull out brake band piston B2 (15) with thrust pin (26) clipped in place.






13. Fit on assembly device (026), bolt to transmission housing and tension.

14. Take out retaining ring (41).






026 Assembly device 201 589 03 59 00

15. Release tension of assembly device (026), take off brake band piston B1 (37) as well as cover (40) and return springs (35, 36).

16. Unscrew assembly device (026).






17. Pull out brake band guide B1 (34).

18. Remove screw plug (33) for thrust body B1.






Note:
On transmission 722.410, first of all remove the transmission protection switch with oil pipe.

19. Unscrew hexagon socket bolts (58), take off retaining plate (57) and vacuum unit (60) with thrust pin.

20. Unscrew bolt (55) and take off starter lockout switch (53).

Inatallatlon Note
Tightening torque 8 Nm.






21. Take out thrust body B1 (31) and modulating pressure control valve (59).






22. Unscrew kick-down solenoid valve (61).

23. Engage parking lock. Unscrew twelve-point collar nut (62) using a wrench socket and pull off joint flange (64).

Wrench socket 126 569 02 09 00






Note on vehicles with solenoid valve (Y3/2) for Cat heating.
On vehicles with transmission shift point retard by solenoid valve (Y3/2), connect pressure line to measuring connection for governor pressure ("MR").






24. Take off washer (65).

25. Unscrew bolts (71).

26. Detach rear cover (70) by means of light blows using a plastic-headed hammer, and remove.

27. Disassemble rear cover.






28. In transmissions with pressed-on pulse disc electronic speedometer, take off parking lock gear (73) with rotor, parking pawl (74) and spreader spring (75).






29. In transmissions with mechanical speedometer, take off oil pipe (102), parking lock gear (73) with helical gear, parking pawl (74) and spreader spring (75).







30. Remove plastic guide (80) by pulling upwards, then take off roller (81).






31. Unscrew hexagon socket bolt (82a), pull out shaft (76) and take Out detent plate (82) together with resilient linkage.






32. Remove snap ring (123) from input shaft (68) and take out helical gear (78)





Ring pliers 000 589 52 37 00

33. Remove retaining ring (116) from input shaft (68)






34. Unscrew hexagon socket bolt (45) and take off secondary pump (20).

Note:
On vehicles without secondary pump as of June '91, unscrew cover.






35. Take off O-ring (18) and intermediate plate (19) of the secondary pump.






36. Press in cover (46) and remove retaining ring (47).

37. Pull out cover (46).






38. Press retaining ring together (43) and remove centifugal governor (50).

Pliers 201 589 00 37 00






39. Unscrew bolts of front cover

Installation Note
Tightening torque 13 Nm.

40. Screw two bolts into the tapped hole (arrows) and use these to pull out front cover (10).

Note:
Do not use the two bolts to press off the cover.If necessary, detach cover using a screwdriver.






41. Grip gear set at input shaft (87) and pull forwards carefully to remove.

42. Pull clutch K1 (83) together with brake band B1 (30) off the gear set.

43. Take off discs of (B3) (arrow).






44. Take out damping spring (134).






45. Take thrust pin out of brake band (27).


46. Take out clutch K2 (100). Disassemble clutch K2, assemble and measure.






47. Take off thrust washer (113).






48. Unscrew hex bolts (114). Opposite this, screw in two bolts approx. 80 mm long. Detach the supporting flange (79) from housing by means of hammer blows on the two bolts.

Installation Note
Tightening torque 11 Nm.






49. Position brake band B2 (27) at an angle, press together and take out.

Note:
Transverse cracks in the brake band lining B2 are not a cause for concern.

50. Pull out thrust body B2 (29).

51. Remove seals, test connection plugs, etc. still in housing.