Part 2
Gearcase And Torque Converter HousingIMPORTANT: It is essential the greatest cleanliness is maintained when working with the transmission. Contamination can seriously affect the transmission's function and service life.
To Assemble
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 ft. lbs.)
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 gearcase. 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 ft. lbs.)
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 ft. lbs.)
63. Press in a new seal into the gearcase. 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 Handbrake 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 gearcase (short bolts). Tighten the bolts.
Tightening torque 5.5 Nm (4 ft. lbs.)
67. Fit the cover with two bolts.
Tightening torque 5.5 Nm (4 ft. lbs.)
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 ft. lbs.)
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 gearcase and torque converter housing. Use 30 02 599 Cleaning anent . Keep the surfaces free from grease.
71. Fit a new seal into the gearcase and apply an approximately 1 mm thick bead of 87 81 841 Silicone flange sealant to the gearcase as illustrated. Fit the torque converter housing.
72. Apply 74 96 284 thread locking adhesive to the internal bolts. Fit the bolts (different lengths). Tighten the bolts.
Tightening torque 25 Nm (18 ft. lbs.)
73. Clean the magnetic surface on the drain plug and fit it with a new gasket.
Tightening torque 40 Nm (30 ft. lbs.)
74. Turn the gearcase so that the shaft points approximately 45° 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 gearcase. Press the pump unit in place carefully. Tighten the bolts carefully and alternately.
Tightening torque 25 Nm (19 ft. lbs.)
78. Turn back the gearcase 45°
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 a Internally.
Tightening torque 10 Nm (7 ft. lbs.)
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 gearcase.
84. Plug in the connectors for the eight solenoids and fit the oil temperature sensor.
85. Clean the inside of the valve housing cover. Remove all gasket remains from the contact surfaces of the cover and gearcase. Clean the sealing surfaces with 30 02 599 Cleaning anent .
86. Apply an approximately 1 mm thick bead of 87 81 841 Silicone flange sealant to the cover and fit the cover to the gearcase. Apply 74 96 284 Thread locking adhesive to the bolts (different lengths) and tighten the bolts alternately.
Tightening torque 25 Nm (19 ft. lbs.)
87. Turn the gearbox 180°
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 ft. lbs.)
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 ft. lbs.)
90. Engage neutral and fit 87 92 467 Adjustment tool, near 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 ft. lbs.)
91. Remove the adjustment tool.
92. Change the 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 91766 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. Prise 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 gearcase 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. Remember to clean the oil cooler with 87 91 824 Flushing equipment.