Steps 51 Through 103

51. Fit the planetary gear set.
52. Fit the thrust bearing race, greased with Vaseline, to the planetary gear set.
53. Grease the thrust bearing of the planet ring gear with Vaseline and fit the bearing to the front side of the planet ring gear. Place the planet ring gear on the planet gear set.





54. Grease the bearing race of the planet ring gear with Vaseline. Fit the bearing race.
55. Grease the thrust bearing with Vaseline and fit it to the sun gear shaft.
56. Fit the sun gear unit to the planetary gear set.
57. Grease the thrust bearing of the sun gear with Vaseline and place the bearing on the sun gear. Make sure that the bearing is fitted with the black side facing upwards.
58. Centre the discs and plates with a screwdriver. Fit the ring gear and clutch C1 as a unit. Turn the idler and C1 towards each other so that the planetary gear set meshes with the ring gear.





59. Check that the ring gear and clutch C1 have fallen into place by measuring as illustrated. The distance should be 51 mm.





60. Fit the oil pipe. Use a shatterproof plastic mallet. Be careful not to bend or damage the pipe.
61. Place a clip on the pipe and tighten the screw.
Tightening torque 5.5 Nm (4 ft. lbs.)
62. Fit the oil pipe of clutch C3 as illustrated. Use a shatterproof plastic mallet. Be careful not to bend or damage the pipe.
63. Fit the bearing race into position on the rear cover. Grease the bearing race with Vaseline. Fit the bearing race and thrust bearing to the C1/C2 unit.





64. Fit the C1 accumulator to the end cover.





65. If the end cover is changed, fit oil sealing rings to the needle bearing housing. Do not stretch the rings more than necessary.
66. Fit a new O-ring greased with Vaseline to the shaft of Cl/C2
67. Clean the sealing surfaces with cleaner 30 02 599. Keep the surfaces free of grease and oil.





68. Apply a 1 mm thick bead of flange sealant 87 81 841 to the rear cover.
69. Grease four new sealing rings for the oil holes with Vaseline and fit them to the gearcase.





70. Fit the end cover to the gearcase. Apply thread sealant 74 96 284 to the bolts and tighten them in sequence (different lengths).
Tightening torque M6 10 Nm (7 ft. lbs.)
Tightening torque MS 25 Nm (18 ft. lbs.)
71. Turn the gearbox so that the turbine shaft points 45° downwards.





72. Apply Vaseline to the O-ring of the oil pump unit. Align the plate package using a small screwdriver. Fit thrust washers greased with Vaseline to brake B1/B2.





73. Fit freewheel F1 and the bearing race of brakes B1 and B2 to the oil pump unit. Grease the bearing race of F1 with Vaseline and fit it.





74. Place the oil pump unit so that the bolt holes are aligned with those of the gearcase. Carefully press the pump unit into place. Carefully tighten the bolts alternately.
Tightening torque 25 Nm (19 ft. lbs.)
75. Turn the gearbox back 45°





76. Check that the axial play of the turbine shaft is 0.37 - 0.9 mm. Use gauge 78 40 622 and stand 87 90 727.





77. Fit the two sealing rings.





78. Connect the piston rod of the manual valve with the manual valve control on the valve housing unit. Thread the bolts. Make sure the gasket does not get folded.





79. Fit the gasket to the cover. Fit the bolts of the cover. Tighten all the valve housing bolts in sequence.
Tightening torque 10 Nm (7 ft. lbs.)
80. Grease a new O-ring with Vaseline and fit it, as well as the grommet and wiring harness for the solenoids, to the gearcase.
81. Connect the connectors to the four solenoids and secure the wiring.





82. Clean the inside of the gearcase cover. Remove any gasket remains from the contact surfaces of the cover and gearcase. Clean the sealing surfaces with cleaner 30 02 599. Apply a 1 mm thick bead of sealant 87 81 841 to the cover and fit the cover to the gearcase. Apply thread sealant 74 76 284 to the bolts (different lengths) and tighten them in sequence.
Tightening torque 25 Nm (19 ft. lbs.)





83. Fit the fluid temperature sensor to the gearcase. Fit a new O-ring greased with Vaseline.
Tightening torque 10 Nm (7 ft. lbs.)
84. Fit the protective plate of the fluid temperature sensor with a nut, washer and bolt.
Tightening torque, bolt 25 Nm (19 ft. lbs.)
Tightening torque, nut 10 Nm (7 ft. lbs.)
85. Clean the sealing surface of the plate cover and apply a 2 mm thick bead of sealant, part no. 87 81 841. Fit and tighten the bolts.
Tightening torque 7.5 Nm (6 ft. lbs.)
86. Turn the gearbox 180°





87. Fit new O-rings to the speed sensors. Clean the speed sensors and make sure that there are no metal filings on the magnets. Grease the O-rings with Vaseline. Fit the two speed sensors in their respective positions. Note that for models in which the wiring is connected directly to the sensors, the wires are of different lengths. Long cable input shaft (A), short cable = output shaft (B). Plug in the speed sensor and temperature sensor connectors. Tighten the bolts.
Tightening torque 5.5 Nm (4 ft. lbs.)





88. Fit the gear selector position sensor. Fit the holder for the grommet. Tighten the gear selector position sensor bolts first (important). Then tighten the nut on the gear selector position sensor and bend up the lock plate.
Tightening torque 8 Nm (6 ft. lbs.)





89. Engage neutral and fit adjustment tool 87 92 467. Undo the gear selector position sensor bolts and adjust the sensor so that the mark is visible in the centre of the groove on the adjustment tool. Tighten the bolts.
Tightening torque 25 Nm (18 ft. lbs.)
90. Remove the adjustment tool.
91. Turn the gearbox 90°.
92. Change the torque converter seal. See adjustment/replacement Torque converter seal.





93. Fit the torque converter. Use holder 87 92 681 or 87 91 766. Fit assembly retainer 87 92 277 or 87 92 574.
94. Check that the torque converter is correctly positioned by placing a steel ruler on the mating face of the torque converter. Measure the distance between the mating face and the contact surface of the drive plate on the torque converter. The distance should be:
4-cyl. 9 mm.
6-cyl. 15 mm.
95. Remove holder 87 92 681.





96. Fit new drive shaft seals. Use drift 83 90 122





97. Tie together the wiring harness with cable ties.





98. Pry the type plate off the replaced gearbox with a screwdriver.





99. Flatten the plate with a hammer. Enlarge the hole with a conical drift using a M10 nut as a support. Place the plate on the new gearcase and press it in place. Use an M8 nut over the centre pin as a support and seal with a hammer.





100. Refit the engine mounting and lift the gearbox off the stand.
101. Remove holder 87 92 392 from the gearbox.
102. Fit the selector wire mounting.
103. Fit the gearbox to the car. Don't forget to clean the oil cooler with flushing equipment 87 91 824.