Disassembly

Important
It is very important to observe great cleanliness when working on the gearbox. Dirt particles can seriously damage the function and service life of the gearbox.





1. Drain the oil from the transmission in the car before starting removal. Remove the gearbox from the car. Fit the dipstick pipe.
2. Plug the shaft openings. Clean the exterior of the gearbox. Use plug 91 32 929, seals 91 32 937 and 87 92 665. Plug the vent pipe.
3. Unplug the connectors and remove the wiring harness.
4. Remove the dipstick pipe.





5. Fit holder 87 92 392 on the gearbox using flange screw M8x25.

Note: Organize the workplace so that groups of associated parts that are dismantled can be kept together to facilitate refitting.

6. Mount the gearbox in stand 78 74 878.





7. Bend out the lock washer for the gear position sensor nut and loosen the nut slightly.
8. Remove the gear position sensor.





9. Unplug the connectors to the speed sensors and the temperature sensor. Remove the speed sensors.





10. Fit tool 87 91 766 into the torque converter. Remove holder 87 92 574. Remove the torque converter.





11. Turn the gearbox through 180 degrees in the stand.





12. Remove the cover plate and the temperature sensor.
13. Remove the plate cover on the torque converter shell.





14. Remove the bolts securing the valve body cover and knock loose the cover using a splinter-free plastic mallet.

Important
Take care that the sealing surfaces are not damaged.





15. Disconnect the solenoid electric connections. Lift the system pressure solenoid shell slightly using a small screwdriver to access the catch. Unhook the cable. Pull out the cable and grommet from the gearcase. Retain the holder.
16. Remove the valve body bolts (only bolts with 10 mm head). Retain the small cover.
17. Unhook the manual valve connecting rod from the valve control and remove the valve body.





18. Remove the two seals.





19. Remove the bolts securing the oil pump to the gearcase.
20. Pull off the oil pump and brake unit B2 from the gearcase using puller 87 92 699.





21. Remove the brake hub and freewheel F1.





22. Turn the gearbox through 90 degrees in the stand.





23. Remove the torque converter shell. Knock loose the housing with a plastic mallet,
Remove the small seal.





24. Lift out the differential unit.
25. Remove the oil strainer and the cover plate.
26. Remove the oil channel plate from the gearcase.





27. Remove the torsion spring and the ratchet spindle for the handbrake.
28. Remove the handbrake control rod and the gear position disc. Release the detent spring.
29. Remove the shaft seal for the selector lever shaft.





30. Remove the holder for the handbrake control rod and the detent spring.
31. Remove the handbrake ratchet and guide pin.





32. Remove the holder and torsion spring.





33. Remove the cover with O-rings, plunger and spring.
34. Lift out the output shaft assembly with thrust bearing and bearing races.





35. Lift out the C3 clutch and bearing race. Retain the thrust bearing.
36. Lift out the B4 brake bands from the gearcase.





37. Remove the circlip for the freewheel F3 from the gearcase. Lift out F3. Retain the small clip.





38. Remove the oil sealing rings by pressing one side of the ring towards the groove and unhooking the ring.





39. Turn the gearbox through 180 degrees





40. 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.





41. Remove the bolts securing the end cover. Knock loose the cover with a plastic mallet. Remove the four seals.





42. Remove the pipe for the C3 solenoid. Use sliding hammer 83 90 270 and hook 87 92 384.
43. Remove the pipe holder and the second pipe. Use sliding hammer 83 90 270 and hook 87 92 384.
44. Remove the bearing and bearing race from the cover and the bearing race from the turbine shaft assembly with clutches C1 and C2.





45. Lift out the turbine shaft unit with clutches C1 and C2. Retain the thrust bearing and thrust bearing race.
46. Lift out the planetary gear sun gear and thrust bearing. Retain the bearing race.





47. Remove the rear ring gear. Retain the thrust bearing and bearing race.
48. Lift out the planetary gear unit with the large thrust bearing.





49. 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.
50. Retain the thrust bearing and bearing race.
51. Remove the circlip for the spring unit using a screwdriver. Lift out the spring unit.





52. If necessary, remove the accumulator for C1 from the end cover with spring and plunger.
53. Remove the plug from the end cover





54. Carefully apply an air pressure of 4 bar through the oil passage for 63 to remove the B3 plunger as illustrated. Use a pair of blunt nose pliers if the plunger will not come out.
55. Turn the gearbox through 90 degrees.





56. Remove the circlip for the intermediate gear. Use circlip pliers 87 90 180 with tips 87 90 297 and a small screwdriver. Remove the intermediate gear.
57. Turn the gearbox through 90 degrees





58. Remove the drive shaft seal using a hammer and screwdriver.





59. Fit puller 87 91 683 and 87 91 675 and remove the bearing race from the gearcase by heating the case with a hot air gun for about 5 minutes. Pull out the bearing race and retain the shim.





60. Remove the brake band holders and the remaining plugs in the gearcase (do not get the plugs mixed up).





61. Remove the screw and pipe clamp from the torque converter shell.
62. Pull up both ends of the pipe with sliding hammer 83 90 270 and hook 87 92 384. Remove the pipe. Take care not to damage the pipe.
63. Remove the oil channel plate (three bolts). Remove the three magnets.





64. Fit puller 87 91 675 and 87 91 683. Heat the bearing seat for about 5 minutes with a hot-air gun and pull out the roller bearing.
65. Knock out the shaft seal.





66. Remove the bearing race for the taper roller bearing in the torque converter shell by heating around the bearing seat with a hot-air gun for about 5 minutes. Pull out the bearing using puller 87 91 683 and 87 91 675.
The bearing need only be removed when changing the torque converter shell or differential bearing.