Section 1
Disassembly
Transmission Component Installation Details (Section 1)
3 - AT oil pan; 3a - Gasket; 4, 7, 8, 108, 140 - Bolts; 5 - Oil filter; 13 - Bottom cover; 14 - Large intermediate plate; 15 - Oil guide pipe; 98 - Gear shift cable; 135 - Locking pin; 142 - Retaining spring; 151 - Adjusting spring and locking gasket; 152 - Locking lever; Y3/2 - Solenoid valve
1. Remove the gearbox from the rotation converter.
2. Remove the vacuum-actuated gear shift cable (98).
3. Remove the solenoid valve (Y3/2).
4. Disconnect the gearbox from the brackets.
5. Remove the valve body (9).
6. Remove the bottom cover (13) with the intermediate plate (14).
7. Remove the single-channel valves, B2 brake band, oil deflector and temperature flap from the gearbox housing.
Assembly
Assembly is carried out in the reverse order of disassembly.
Section 2
Disassembly
Transmission Component Installation Details (Section 2)
10 - Front cover with secondary pump; 17, 44a, 48 - Sealing rings; 18, 45, 58, 73 - Bolts; 19, 72 - Gaskets; 20 - Secondary pump; 43 - Retaining ring; 44 - Ventilation plug; 46 - Lid; 50 - Centrifugal regulator; 59 - Pressure modulator valve; 59a - Finger; 60 - Pressure modulator; 62 - Nut; 4 - Flange; 70 - Gearbox rear cover; S16/4 - Starter interlock switch
1. Disassemble the gearbox.
2. Remove the modulator (60).
3. Remove the starter interlock switch (S16/4).
4. Remove the secondary pump (see section Removal, maintenance and installation of the secondary pump (AT up to No.3652931)).
5. Remove the vent plug (44) and sealing ring (44a).
6. Remove the front gearbox cover (10) with the secondary pump (20).
7. Remove the flange (64).
8. Remove the retaining ring (43), cover (46) and sealing ring (48).
9. Remove the rear gearbox cover (70).
Assembly
Assembly is carried out in the reverse order of disassembly.
Section 3
Disassembly
Transmission Component Installation Details (Section 3)
73 - Plastic guide; 74 - Parking brake pawl; 75 - Tension spring; 77 - Sealing ring; 82 - Locking plate with traction; 82a - Bolt; 36 - Output shaft; 165, 188 - Retaining ring; 170 - Ring gear; 172 - Overdrive clutch support disc; 192 - Overdrive clutch piston; Y3/1x1 - Cork
1. Disassemble the gearbox (see sections 1 and 2).
2. Remove the tension spring (75) and unhook the parking brake pawl (74).
3. Remove the plastic guide (73).
4. Remove the locking plate (82) with the rod by unscrewing the bolt (82a).
5. Remove the plug (Y3/1x1) of the solenoid valves and the sealing ring (77) from the gearbox housing.
6. Remove the overdrive brake and clutch.
Assembly
Assembly is carried out in the reverse order of disassembly.
Section 4
Disassembly
Transmission Component Installation Details (Section 4)
15 - Brake piston B2; 17 - Brake piston cover B2; 23, 41 - Retaining rings; 27 - Brake band B2; 28 - Finger; 29 - Brake bearing B2; 30 - Brake band B1; 31 - Brake bearing B1; 33, 60 - Bolts; 34 - Brake guide B1; 37 - Brake piston B1; 40 - Brake piston cover B1; 79 - Support flange; 83 - Clutch K1; 85 - LB3 Brake Disc Spring Ring; 87 - Planetary Pair; 88 - Radial oil seal; 88a - Plastic Brake Guide Ring B2; 90, 91, 197 - Sealing rings; 95, 96 - Gaskets; 97 - Thrust bearing; 100 - Clutch K2; 113 - Support gasket; 115 - Teflon rings; 133 - Multi-disc brake B3; 134 - Damper spring; 167 - Output shaft; 565 - AT overload protection sensor
1. Disassemble the gearbox (see sections 1, 2 and 3).
2. Remove the B1 brake bearing (31) from the housing by unscrewing the bolt (33) or the AT overload protection valve (S65). 3. Attach the puller (026) and screw it onto the gearbox. Secure the puller (026). Remove the retaining ring (41).
4. Loosen the puller (026). Remove the piston with the brake pin B1 (37) together with the cover (40) and return springs (35) and (36).
5. Remove the brake band guide of brake B1 (34). Replace the sealing ring in the gearbox housing.
6. Remove clutch K1 (83) with brake band B1 (30). Remove multi-disc brake B3 (arrow). Carefully remove drive shaft (87).
7. Remove the damper spring (134) from the gearbox housing.
8. Remove the brake piston B2 (15) by pressing the brake cover B2 (17), removing the retaining ring (23).
9. Remove the plastic ring (88a) and the radial oil seal (88).
10. Remove clutch K2 (100).
11. Remove the brake band of brake B2 (27).
12. Remove the support ring (113) from the flange (79).
13. Remove the locking flange (79) from the gearbox housing by unscrewing the bolts (80).
Assembly
1. Install the flange (79) with the sealing ring (197) and the Teflon rings (115) into the gearbox housing. Before installing the flange (79), make sure that the lubricating constrictor is installed in the flange (79), - to install the flange (79), use two bolts approximately 80 mm long.
2. Install the support gasket (113) onto the flange (79).
3. Insert the B2 brake bearing (29) with the pin (20) into the gearbox housing. The larger diameter of the pin (28) must be directed towards the B2 brake band (27).
4. Insert the plastic guide ring (88a) and radial oil seal (88) into the gearbox housing. When installing, the sealing edge must face the piston cover (17) of the brake band.
5. Check the stop part of the brake B2 (29) for distortion. The stop part, hole and eye (arrows) must be in the same position when removed.
6. Install a new sealing ring into the gearbox housing. Insert the brake thrust part B2 (29) with the eye upwards.
7. Compress the brake band of brake B2 (27) as much as possible and insert it into the housing, - the brake band can be installed using the retaining ring for piston B2 (23).
8. Lubricate the grooves on the output shaft (167) and insert the Teflon rings (167a).
9. Install clutch K2 (100) on the planetary pair using the tool (030).
10. Insert the planetary pair into the gearbox housing by turning the drive shaft (87).
11. Install the gearbox with the drive shaft (87) vertically upwards.
12. Check the installation of the planetary pair. The planetary pair is installed correctly when the upper edge of the coupling support (arrow) is lower than the support surface (138) of the outer multi-disc brake LB3. Install the spring (134). The projection (arrow A) on the spring must be installed inward. The damper spring must be installed in the groove (arrow B) in the gearbox housing.
13. Install the brake piston B2 (15) by pressing the brake piston cover B2 (17) and inserting the retaining ring (23).
14. Install and check the clearance in the LB3 multi-disc brake.
15. Install clutch K1 (83) on planetary pair (87).
16. Install the brake band B1 (30).
17. Check the clearance of the brake band of brake B1 (see section Measuring the clearance in the brake B1) - the nominal value is 1.8-2.4 mm.
18. Check the gap in the brake band of the B2 brake - the nominal value is 5.5-6.0 mm.
19. Check the clearance in the B3 multi-disc brake (see section Installation and clearance check in multi-disc brake B3) - the nominal value is 1.5-2.0 mm.
20. Further assembly is carried out in the reverse order of removal.
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