Disassembling And Assembling Transmission

Disassembling

Absolute cleanliness is very important when working on an open transmission. Perfect transmission function requires that there be no dirt on transmission parts, command valves or in oil circuits. Consequently disassembled parts must be washed thoroughly, oil bores flushed and dried.

Never use gasoline to wash rubber seals, which would be damaged. Only use alcohol for cleaning.

Also make sure that wool rags are not used on parts, because even minute contamination <e. g. lint) could lead to disturbances.

1. Detach final drive and remove bearing assembly with drive pinion (see page 39 - 22).

2, Remove final drive housing, centrifugal governor and modulation pressure valve housing (see page 37 - 21).

Note

It is essential to first take off the vacuum box for modulation pressure prior to removing the final drive housing.

3. Pull parking lock gear off of output shaft.

4. Remove front converter housing and torque converter (see page 32 - 1).

6. Remove solenoid valve.

7. Remove snap ring for cover of brake band B 2 piston and take off cover.

8, Install Special Tool 9305 and press out piston carefully.

Special Trans Band

9. Attach Special Tool 9304 for cover of brake band B 1 piston. Preload piston and remove ?nap ring.

Maladjusted Mesh Preload

10. Release and unscrew special tool.

11. Remove cover, piston and springs of brake band B 1.

Ezky Opasek

15. Remove brake band B 3 forward.

16. Pull input shaft out of gear assembly.

12, Remove pressure pins for B 1 and B 2, Note

Mark pressure pins for reinstallation.

A - Pressure pins

13. Swing transmission in assembly stand to horizontal position.

14, Remove adjusting screw B 3 and take out both pressure pins.

15. Remove brake band B 3 forward.

16. Pull input shaft out of gear assembly.

17. Hold brake band B 1 on the drum with a snap ring from cover of brake band B 2 piston and remove gear assembly with brake bands.

18. Drive out output shaft with a plastic hammer.

Assembling

Use specified ATF on bearings and moving parts when assembling the transmission,

1. Install output shaft with ball bearings in trans~ mission case and drive in with a plastic hammer.

2. Install parking lock gear.

3. Attach final drive housing with centrifugal governor, modulation pressure valve housing and pressure piston (see page 37 - 21).

4. Install the shims (either those noted while disassembling or those of redetermined thickness) with the bearing assembly and tighten drive pinion nut to specified torque (see pages 39 - 23 and 39 - 29).

5. Install brake band B 2 (steel band with radial groove liner) and brake band guide in transmission case.

6. Lubricate and install radial bearing.

7. Hold brake band B 1 (steel band with smooth liner) on brake band drum with the snap ring for piston of brake band B 2.

8. Install gear assembly with brake band B 1. guiding the support lever for the oil distribution sleeve into groove of transmission case

Note

When guiding gear assembly into the transmission case, make sure that segment spline of sun gear on the output shaft meshes correctly in drum of brake band B 2.

9. Install input shaft in gear assembly.

10. Install brake band B 3 (thick steel band with radial groove liner) in transmission case from front. Insert both pressure pins in brake band and screw new adjusting screw coated with a sealant in transmission case so far. until brake band is held.

11, Turn transmission until input shaft faces up.

Axial play will be the difference between "A" and "B".

12. Measure axial play of gear assembly. It should be 0. 4 to 0. 6 mm.

Adjust axial play to 0, 4. .. 0. 6 mm by using shims of pertinent thickness on the input shaft.

install rear converter housing with gasket and tighten four mounting bolts to specified torque.

Check distance from upper edge of input shaft to upper edge of stator shaft with a depth gauge. This distance is "A".

Note

Prior to checking the axial play of the gear assembly, it will be essential to adjust the bearing assembly and tighten the drive pinion nut to specified torque.

15. Install piston of brake band B 2 by guiding brake band piston into transmission case with Special Tool 9305 and making sure that the pressure pin has proper fit in bote of brake band B 2.

19, Measure distance of dead travel for pistons of brake bands B 1 and B 2. This is done by moving piston of brake band B 2 into lift position with air pressure supplied through lift pressure bore and checking distance "b". Then move the brake band piston into shift position with air pressure supplied through the shift pressure bore and recheck distance "b". The difference of both distances is dead travel "L".

16, Use a new O-ring on cover of B 2 brake band piston and install with a spring.

Note

Apply a light coat of ATF on Oring. 17. Install snap ring for cover.

Check distance "a" while springs hold the piston of brake band B 1 in lift position. Then move this piston to shift position with air pressure supplied through shift pressure bore B 1 and recheck distance "a". The difference will be dead travel "L".

Dead travel "L" of pistons in brake bands Unscrew adjusting screw by 1 3/4 turns and

B 1 and B 2 should be 3, 0 to 4. 0 mm. recheck gap "A". The difference between both distances is the dead travel, which should be at least 3 mm.

Note

Dead travel "L" excessive - use longer pressure pin. Dead travel "L" insufficient - use shorter pressure pin.

Hold the adjusting screw to prevent maladjustment. Tighten counternut and grind off head of adjusting screw.

20. Adjust brake band B 3.

20. Adjust brake band B 3.

Screw in the adjusting screw after loosening the counternut and tighten to 5 Nm (0. 5 kpm). Check gap "A" on brake band.

No.

Description

Qty.

Note When Removing Installing

Special instructions

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