| Removal and Installation General notes - Clean the transmission assembly to prevent the ingress of dirt when reassembling.
- Place the removed parts neatly to one side to facilitate damage assessment and reassembly.
- If, during repair work, abraded particles are found in the transmission fluid (particles from the clutch or metal swarf), the transmission must be dismantled completely and cleaned.
- The oil pipes, oil cooler and torque converter should also be cleaned carefully. In the case of extreme soiling they should be renewed.
|  | NOTE: In the case of abraded particles of metal, the valve body, oil pipes, oil cooler and torque converter should be renewed. | - The brake bands and friction plates must not be allowed to come into contact with cleaning agent.
- The only permitted cleaning agent is paraffin.
- When using new clutch plates, immerse them in automatic transmission fluid for approximately 30 minutes prior to installation.
- Before taking measurements, compress all the clutches in which axial play is detected to squeeze the oil out from in between the plates.
- All sliding parts should be lubricated with automatic transmission fluid before installation.
- Thrust washers and needle roller bearings should be positioned using Vaseline when reassembling.
- In the following text, O/D stands for ”Overdrive".
- The thrust washers and needle roller bearings are identified by their code number. This code number relates to the Parts Microfiche.
| 1 | Sump | | 2 | Oil strainer | | 3 | Oil strainer gasket | | 4 | Rear servo piston | | 5 | Valve Body Assembly | | 6 | Adaptor plate with gaskets | | 7 | Sump gasket | | 8 | Front servo piston | | 9 | Centre servo piston | | 10 | Vacuum diaphragm unit | | 11 | Throttle valve | | 12 | Start inhibitor switch | | 13 | Torque converter housing | | 14 | Seal - oil pump housing | | 15 | Input shaft | | 16 | Torque converter | | 17 | Shift and park lock mechanism | | 18 | Seal - Transmission Extension Housing | | 19 | Transmission extension housing | | 20 | Parking pawl | | 21 | Gasket - transmission extension housing | | 22 | Output shaft | | 23 | Governor | | 24 | Oil seals | | 25 | Governor hub | | 26 | Thrust washer (-7B368-) | | 27 | Adaptor plate gasket | | 28 | Adaptor plate | | 29 | Oil pump gears | | 30 | Oil pump shaft gasket | | 31 | Oil pump | | 32 | Thrust washer (-7D014-) | | 33 | Rectangular‐section seal | | 34 | O/D brake band | | 35 | Hydraulic piston inner seal | | 36 | Hydraulic piston outer seal | | 37 | Hydraulic piston | | 38 | Compression springs | | 39 | Spring retainer | | 40 | Circlip. | | 41 | Plate pack | | 42 | Support plate | | 43 | Support plate circlip | | 44 | Drive plate | | 45 | Sun gear | | 46 | Needle roller bearing (-7D234-) | | 47 | Planetary gear carrier | | 48 | Axial needle roller bearing (-7L495-) | | 49 | Ring gear | | 50 | O/D one‐way clutch | | 51 | Centre shaft | | 52 | Centre shaft circlip | | 53 | Needle roller bearing (-7F374-) | | 54 | Centre carrier circlip | | 55 | Centre carrier | | 56 | Centre carrier oil seals | | 57 | Needle roller bearing (-7D014-) | | 58 | Centre brake band | | 59 | Hydraulic piston inner seal | | 60 | Hydraulic piston outer seal | | 61 | Hydraulic piston | | 62 | Compression springs | | 63 | Spring retainer | | 64 | Circlip. | | 65 | Plate pack | | 66 | Support plate | | 67 | Support plate circlip | | 68 | Piston rings | | 69 | Hydraulic piston inner seal | | 70 | Hydraulic piston outer seal | | 71 | Hydraulic piston | | 72 | Compression springs | | 73 | Spring retainer | | 74 | Hydraulic piston damping ring | | 75 | Circlip. | | 76 | Plate pack | | 77 | Support plate | | 78 | Support plate circlip | | 79 | Needle roller bearing (-7D234-) | | 80 | Bronze bush (-7D045-) | | 81 | Needle roller bearing (-7F374-) | | 82 | Planetary gear carrier with needle roller bearing (-7D234-) | | 83 | Inner circlip | | 84 | Sun gear | | 85 | Input shell | | 86 | Outer circlip | | 87 | Small circlip - output shaft | | 88 | Large circlip - output shaft | | 89 | Thrust washer (-7D423-) | | 90 | Rear planetary gear carrier | | 91 | Thrust washer (-7D423-) | | 92 | Ring gear | | 93 | Rear brake drum | | 94 | Rear brake band | | 95 | Thrust washer (-7D422-) | | 96 | Rear one‐way clutch | | 97 | Circlip | Non‐clip design, installed positions of thrust washers and needle roller bearings | 1 | Thrust washer (-7D014-) | | 2 | Needle roller bearing (centre shaft) (7L495) | | 3 | Thrust washer (centre shaft) (-7L326-) | | 4 | Thrust washer (direct clutch) (-7D428-) | | 5a | Two thrust washers, or | | 5b | Sintered metal bush, or | | 5c | Thrust washer with needle roller bearing | | 6 | Needle roller bearing (ring gear - intermediate gear set) | | 7 | Thrust washer (rear planetary gear carrier) | | 8 | Thrust washer (rear ring gear) | | 9 | Thrust washer (governor hub) | Clip design only, installed positions of thrust washers and needle roller bearings | 1 | Thrust washer (-7D014-) | | 2 | Needle roller bearing (centre shaft) | | 3 | Thrust washer or needle roller bearing (-7D014-) | | 4 | Needle roller bearing (centre carrier) | | 5 | Sintered metal bush (intermediate gear set) | | 6 | Needle roller bearing (intermediate gear set) | | 7 | Needle roller bearing (ring gear - intermediate gear set) | | 8 | Thrust washer (rear planetary gear carrier) | | 9 | Thrust washer (rear ring gear) | | 10 | Thrust washer (governor hub) | Installation positions, (A4LDE), thrust washers and needle roller bearings | 1 | Thrust washer (-7D014-) | | 2 | Needle roller bearing (-7D014-) | | 3 | Thrust washer (‐7D090‐) | | 4 | Thrust washer (‐7D090‐) | | 5 | Needle roller bearing | | 6 | Thrust washer | | 7 | Thrust washer | | 8 | Thrust washer | | N1 | Needle roller bearing | | N2 | Needle roller bearing | | N3 | Needle roller bearing | | N4 | Needle roller bearing (‐7L495‐) | | | 15‐008Dial indicator fixture | | | 15‐022ADial indicator fixture | | | 17‐002Installer, transmission extension housing oil seal | | | 17-006AMounting bracket | | | 17-007AClutch spring compressor | | | 17‐008Shift lever oil seal installer | | | 17-009-01AOil pump aligner | | | 17-010AOil pump oil seal installer | | | 17-011AOil pump oil seal remover | | | 17‐012Servo piston rod gauge | | | 17‐029Torque wrench, brake band | | | 17‐030Aligner screws, valve body assembly | | | 17‐055Gauge bar | | | 17‐058Clutch spring compressor | | | 17‐067Guide sleeve, centre shaft one‐way clutch | | | 21‐179Separator, oil seal removal | | Depth gauge | | Dial indicator | | Gasket set | | | Vaseline | | | Paraffin | | | Automatic transmission fluid | ESPM‐2C166‐H | Dismantle | | 1. Remove the torque converter. |  | CAUTION: The torque converter is filled with transmission fluid. | • Shake the torque converter and empty it through a fine sieve. • Check the transmission fluid; see General Notes. | | | 2. Pull out the input shaft. | | | 3. Remove the start inhibitor switch. | | | 4. Detach the solenoid switch. 1. Unhook the kick‐down cable. 2. Detach the solenoid switch. | | | 5. Attach the automatic transmission to an assembly stand. | | | | | NOTE: Do not turn the transmission through more than 45°, to avoid any entry of deposits into the transmission. | 6. Drain off the transmission fluid. Check the transmission fluid, see ”General Notes". | | | | | NOTE: Check the residues in the sump (see General Notes). | 7. Detach the sump downwards. Remove the gasket with the torque restrictors (36 off). | | | 8. Remove the oil strainer. Remove the oil seals from the oil strainer. | | | 9. Detach the selector interlock mechanism spring. | | | 10. Remove the rear servo piston. 1. Detach the servo cover and gasket. 2. Withdraw the servo piston. 3. Remove the oil seal. | | | | | NOTE: Hold the manual selector slide. | 11. Remove the valve body. 1. Remove the bolts (x24). Lift the valve body assembly and slide it to the side. 2. Withdraw the selector lever linkage from the manual selector slide. 3. Remove the valve body assembly with the gasket. | Remove oil pump housing seal | | 12. Rework the special tool as required. • File out the open slits to 4,9 mm. • Alter the special tool number to read 17‐011A. | | | | | NOTE: Turn the automatic transmission so that it is horizontal. Push the inner ring on the puller right down. | 13. Remove the oil seal. | | | 14. Remove the torque converter housing and oil pump (8 bolts). | | | 15. Detach the oil pump from the torque converter housing. 1. Remove the thrust washer (-7D014-). 2. Remove the gasket from the adaptor plate. 3. Remove the rectangular‐section seal. 4. Detach the oil pump with the adaptor plate. | | | 16. Dismantle the oil pump. 1. Remove the inner gear. • Detach the oil pump shaft seal. 2. Remove the outer gear. | | | | | NOTE: The oil pump can only be renewed as a complete unit. | 17. Check the oil pump housing and the adapter plate for wear and scoring. | Measure the O/D gear set end float | | 18. Measure the O/D gear set end float (cont.). 1. Put the previously fitted thrust washer (-7D014-) in place using Vaseline. | | NOTE: Do not damage the oil seals. | 2. Fit the oil pump into the O/D gear set. | | | 19. Measure the O/D gear set end float (cont.). 1. Fit the gasket. 2. Set up the dial indicator on the oil pump housing. Position the dial indicator plunger on the oil pump and zero the gauge. | | | | | NOTE: Excessive end float indicates high wear in the front gear set. | 20. Measure the axial play of the O/D gear set (continued). • Position the dial indicator plunger on the transmission housing gasket and read off the measurement. • Repeat the measurement at 180° and calculate the average value. • Required value: 0,38±0,2 mm. | | | 21. Remove the oil pump. Remove the thrust washer (-7D014-). | | | | | NOTE: Mark the O/D brake band so as not to mix it up with the centre brake band. | 22. Remove the O/D brake band. 1. Make a wire clamp and fit it. 2. Remove the adjusting bolt for the O/D brake band. • Remove the plungers. | | | 23. Remove the O/D clutch. | | | 24. Remove the centre shaft. 1. Remove the drive plate and sun gear. 2. Pull out the O/D planetary gear carrier with the centre shaft. 3. Take out the needle roller bearing (-7D014-) or thrust washer (-7L326-). | | | 25. Remove the intermediate lever. 1. Withdraw the pivot pin of the intermediate lever. 2. Take out the intermediate lever. | | NOTE: Mark the intermediate lever so as not to mix it up with the intermediate lever of the centre brake band. | • Remove the pressed steel bracket. | | | 26. Remove the centre carrier. • Remove the bolt (amongst the passages). • Remove the snap ring. | | | 27. Remove the centre carrier (cont.). 1. Withdraw the centre carrier. 2. Remove the thrust ring or needle roller bearing (-7D014-), on a clip design transmission remove the needle roller bearing (-7F374-). • Remove the Viton oil seal from the centre carrier. | | | | | NOTE: Mark the brake band to avoid mixing it up with the O/D brake band. | 28. Remove the centre brake band. 1. Make a wire clamp and fit it. 2. Remove the brake band adjustment bolt. • Remove the plungers. | Remove the intermediate gear set. | | | | NOTE: Clip design only | 29. Remove the intermediate gear set as a unit (shown dismantled). 1. Reverse and direct clutch 2. Forward clutch 3. Needle roller bearing (-7D234-) 4. Sintered metal bush (-7D090-) 5. Crown wheel with hub 6. Needle roller bearing (-7F374-) 7. Front planetary gear carrier 8. Input shell | | | 30. Remove the intermediate gear set as a unit (shown dismantled). 1. Reverse and direct clutch 2. Thrust washer (-7D428-) 3. Forward clutch 4. Needle roller bearing (-7D234-) 5. Sintered metal bush (-7D090-) 6. Ring gear with hub 7. Needle roller bearing (-7F374-) 8. Front planetary gear carrier 9. Input shell | | | 31. Remove the reverse and direct gear clutch. | | | 32. Remove the forward clutch. 1. Thrust washer (-7D428-) 2. Forward clutch 3. Needle roller bearing (-7D234-) with sintered metal bush | | | 33. Remove the ring gear. 1. Ring gear with hub 2. Needle roller bearing (-7F374-) • Take out the sintered metal bush (-7D090-). | | | | | NOTE: The needle roller bearing in the planetary carrier cannot be removed. | 34. Remove the front planetary carrier. | | | 35. Remove the input shell. | | | 36. Remove the rear planetary gear set. 1. Remove the planetary set circlip. 2. Remove the thrust washer (-7D423-). | | | 37. Remove the rear planetary gear set (cont.). 1. Planetary set 2. Thrust washer (-7D423-) | | | | | NOTE: Mark the intermediate lever to avoid mixing it up with the O/D brake band intermediate lever. | 38. Remove the intermediate lever from the centre brake band. 1. Withdraw the pivot pin from the intermediate lever. 2. Remove the intermediate lever. | | | | | NOTE: Move the transmission until it is level. | 39. Remove the front and centre servo piston. • Push the servo piston cover in slightly and remove the circlip. • Remove the servo piston and compression spring, applying compressed air if necessary. • Remove the cover from the servo piston. | | | 40. Check the servo piston. • Check the servo piston for wear or excessive play between the piston and the bore. 1. If necessary, renew the front or centre servo piston. 2. Remove the oil seal from the rear servo piston. • Check that the oil seals are not damaged or hardened. | Remove transmission extension housing seal | | 41. Remove the oil seal from the transmission extension housing. | | | | | NOTE: The driveshaft bearing bush in the transmission housing extension is not available separately. | 42. Remove the transmission extension (six bolts). • Remove the gasket. • Check the condition of the driveshaft bearing bush. | | | 43. Remove the parking pawl from the transmission extension housing. 1. Remove the parking pawl. 2. Remove the return spring. 3. Remove the pivot bolt. | | | 44. Remove the ring gear. 1. Detach the circlip. 2. Remove the ring gear. 3. Take out the thrust washer (-7D422-). | | | 45. Remove the output shaft. • Withdraw the output shaft complete with the governor and thrust washer (-7B368-). • Check the running surface of the oil seals in the housing for wear. | | | 46. Remove the rear brake drum with the brake band. | | | 47. Check the one‐way clutch. • Fit the brake drum on to the inner ring of the one‐way clutch in the transmission housing. • Turn the brake drum • Clockwise = freewheel • Anti‐clockwise = lock | | | | | NOTE: See also step | 48. Remove the throttle valve unit. 1. Remove the vacuum canister. 2. Withdraw the actuating pin. 3. Take the O‐ring off the vacuum canister. 4. Pull out the throttle valve. | | | 49. Remove the throttle pressure valve. | Remove selector lever seal | | 50. Exploded view of shift and park lock mechanism. 1. Kickdown shaft 2. Actuating rod 3. Notched pin 4. Selector lever 5. Kickdown lever 6. O‐ring 7. Selector lever oil seal 8. Engagement plate | | | 51. Dismantle the shift and park lock mechanism. 1. Detach the kickdown lever. • Remove the O‐ring. 2. Withdraw the notched pin. | | | 52. Dismantle the shift and park lock mechanism (continued). 1. Remove the nut. 2. Pull the selector lever outwards and press the kickdown shaft inwards. 3. Pull out the engagement plate and operating rod. | | | 53. Lever out the selector lever oil seal. | Dismantle O/D gear set | | 54. Check the operation of the one‐way clutch. • Clockwise = lock. • Anti‐clockwise = freewheel. | | | 55. Remove the planetary gear carrier. Remove the needle roller bearing (-7L495-) and the thrust washer. | | | | | NOTE: One‐way clutches with a plastic cage are damaged when removed and cannot be reused. | 56. Remove the one‐way clutch if necessary. • One‐way clutch with plastic cage: 1. Drive the one‐way clutch off the centre shaft using a drift. 2. Remove the circlip. • One‐way clutch with steel cage: • Remove the one‐way clutch and oil baffle. | | | 57. Withdraw the centre shaft from the ring gear. | | 58. Notes on dismantling the clutches. | | NOTE: Do not allow cleaning fluid to come into contact with the clutch plates. | • Check the steel and friction clutch plates for wear, damage or any signs of overheating and renew them if necessary. • If a clutch body is damaged or worn, renew the complete clutch assembly. • Check the hydraulic piston for damage and renew as necessary. | Dismantle centre gear set | | | | NOTE: Clip design only | 59. Exploded view of centre gear set. 1. Reverse and direct clutch 2. Forward clutch 3. Needle roller bearing (-7D234-) 4. Sintered metal bush (-7D045-) 5. Ring gear with hub 6. Needle roller bearing (-7F374-) 7. Front planetary carrier 8. Input shell | | | 60. Remove the reverse and direct clutch from the input shell. | | | 61. Remove the forward clutch. 1. Forward clutch 2. Centre planetary gear set 3. Reverse and direct clutch | | | 62. Remove the centre planetary gear set. 1. Centre planetary gear set 2. Bronze bush 3. Needle roller bearing (-7F374-) | Dismantle O/D clutch | | | | NOTE: See also step | 63. Remove the plate pack. 1. Remove the circlip from the support plate. 2. Remove the support plate with the plate pack (three friction plates and three steel plates). | | | 64. Remove the compression springs. 1. Push the spring retainer down. | | NOTE: Align the recess on the special tool with the ball valve. | 2. Remove the circlip. • Relax and remove the spring retainer. • Remove the compression springs (x20). | | | 65. Remove the hydraulic piston. Remove the inner and outer seal. | | | 66. Check the ball valve. Check that the ball valve moves freely: a rattling noise can be heard when the clutch body is shaken. | Dismantle reverse and direct clutch | | | | NOTE: See also step | 67. Remove the plate pack. 1. Remove the circlip from the support plate. 2. Remove the support plate with the plate pack (four friction plates and four steel plates). | | | 68. Remove the compression springs. 1. Press the spring retainer down. 2. Remove the circlip. • Relax the spring retainer and remove it. • Remove the compression springs (x20). | | | 69. Remove the hydraulic piston. Remove the inner and outer oil seal. | Dismantle forward clutch | | | | NOTE: See also step | 70. Remove the plate pack. • Remove the circlip from the support plate. • Remove the support plate with the plate pack. • Transit with petrol engine: five friction plates and five steel plates, • Transit with diesel engine: four friction plates and four steel plates | | | 71. Remove the compression springs. 1. Press the spring retainer down. 2. Remove the circlip. • Relax the spring retainer and remove it. • Remove the compression springs (x15). | | | 72. Remove the hydraulic piston. • Remove the hydraulic piston by knocking it against a rubber support. 1. Remove the inner and outer seal. 2. Remove the rubber damping spring. | | | 73. Remove the piston rings from the clutch collar. | Dismantle centre planetary gear set | | 74. Remove the planetary gear carrier. 1. Remove the planetary gear carrier. | | NOTE: The needle roller bearing (-7D234-) cannot be removed. | 2. Remove the needle roller bearing (-7F374-). | Dismantle input shell | | 75. Remove the sun gear. 1. Remove the outer circlip. 2. Remove the sun gear. 3. Remove the inner circlip from the sun gear. | Remove one‐way clutch - rear gear set | | 76. Dismantle the one‐way clutch. | | NOTE: The rollers will fall out of the bearing carrier. | 1. Remove the circlip. 2. Remove the roller cage from the rear brake drum. 3. Bearing rollers (10 off) | Dismantle governor | | 77. Dismantle the governor. 1. Detach the governor hub from the output shaft. 2. Detach the counterweight. 3. Detach the governor housing. 4. Remove the centrifugal weight. 5. Remove the valve spring and control valve. 78. Clean the transmission housing and all components thoroughly. | Dismantle valve body assembly | 79. Preparations. • Before dismantling the valve body assembly, cover the workbench with a clean sheet of paper or cardboard. • Remove all the shift valves and check that they can move freely. • Carefully clean the oil passages and components with paraffin, blow out any traces of paraffin with compressed air and check for burring, scoring and deposits caused by gumming. • In the case of damage or abraded particles of metal in the valve body assembly or components, the assembly should be renewed complete. • Lubricate the shift valves with automatic transmission fluid before installation. | | | | | NOTE: Keep the adaptor plate horizontal, otherwise the valve balls, retaining plates and split pins could fall out of the pockets. | 80. Detach the adaptor plate from the valve body assembly. Carefully lift off the adaptor plate and gasket. | | 81. Remove the valves: 1. Five ball valves (from valve body type 92GT‐LC (OHC), 92GT‐MC (diesel)) 2. Two band release delay valves 3. Torque converter pressure relief valve with valve spring 4. Throttle pressure relief valve with valve spring 5. Sixth ball valve (up to valve body type 92GT‐LB (OHC), 92GT‐MB (diesel)) | | | 82. Shift valves from holes 215 and 216. 1. Retaining plate 2. Blind plug 3. Band release accumulator valve - 2nd gear 4. Valve spring 5. Retaining plate 6. Band release accumulator valve - 4th gear 7. Blind plug 8. Retaining pin 9. Servo regulator valve for 3rd‐4th gear overrun cut‐off 10. 3rd‐2nd gear kickdown direct drive clutch control valve 11. 3rd‐2nd gear kickdown servo downshift control valve | | | 83. Shift valves from holes 212, 213 and 214. 1. Retaining plate 2. Valve spring 3. 3rd‐2nd gear kickdown downshift modulating valve 4. 3rd‐2nd gear partial load downshift control valve 5. Retaining pin 6. Blind plug 7. Throttle pressure boost valve | | | 84. Shift valves from holes 210 and 211. 1. Retaining pin 2. Blind plug 3. Valve spring 4. Cut‐in control valve 5. Servo regulator valve for 2nd‐3rd gear overrun cut‐off 6. Retaining plate 7. 1st‐2nd gear transition control valve 8. Partial load downshift control valve | | | 85. Shift valves from holes 208 and 209. 1. Retaining plate 2. Blind plug 3. Shift pressure reducing valve 4. Retaining pin 5. Sleeve 6. Main line pressure booster valve (Transit with diesel engine only) 7. Spring retainer (flat) (Transit with diesel engine only) 8. Valve spring 9. Spring retainer 10. Main line pressure regulating valve | | | 86. Shift valves from holes 206 and 207. 1. Retaining pin 2. Blind plug 3. Reverse gear inhibitor valve 4. Valve spring 5. Retaining plate 6. Kickdown valve 7. Manual selector slide | | | 87. Shift valves from holes 204 and 205. 1. Retaining plate 2. Blind plug 3. Outer pressure boost valve 4. Outer valve spring 5. Inner valve spring 6. Inner pressure boost valve (in selector lever positions 1 and 2) 7. Shift valve - 1st and 2nd gear 8. 2nd gear valve 9. Valve spring | | | 88. Shift valves from holes 202 and 203. 1. Retaining plate with slot 2. Retaining plate 3. Blind plug 4. 2nd‐3rd gear shift valve 5. Valve spring 6. Throttle pressure reducing valve 7. 3rd‐2nd gear downshift boost valve 8. Sleeve for 3rd‐2nd gear downshift boost valve 9. Shift valve for converter lock‐up clutch 10. Throttle pressure reducing valve | | | 89. Shift valves from holes 200 and 201. 1. Blind plug 2. 3rd‐4th gear shift valve 3. Valve spring 4. Throttle pressure reducing valve 5. Blind plug 6. Retaining pin 7. Control valve for converter lock‐up clutch | Assemble valve body assembly | 90. Fit the valves: 1. Five ball valves (from valve body type 92GT‐LC (OHC), 92GT‐MC (diesel)) 2. Two band release delay valves 3. Torque converter pressure relief valve with valve spring 4. Throttle pressure relief valve with valve spring 5. Sixth ball valve (up to valve body type 92GT‐LB (OHC), 92GT‐MB (diesel)) | | | 91. Align the adaptor plate with the valve body assembly. • Place the new gasket on the adaptor plate. • Insert the special tool in the holes indicated. | | | 92. Fit the adaptor plate to the valve body assembly. • Tighten the bolts. • Remove the special tool. | Check servo pistons and clutches | 93. Check the operation of the clutches and servos. | | CAUTION: Oil may escape from the oil passages. | • Apply compressed air (max. 5 bar) to the oil passages marked. • If the relevant component is fitted and operating correctly: • A: there is an audible click when the oil passage is opened • B: the air pressure remains constant when the oil passage is closed. | | 1 | Press back the centre servo piston (B). | | 2 | Actuate the centre servo piston (A). | | 3 | Press back the O/D servo piston (B). | | 4 | Actuate the O/D servo piston (A). | | 5 | Actuate the O/D clutch (B). | | 6 | Engage the reverse and direct clutch (A). | | 7 | Engage the forward clutch (A). | | | 94. Locate the valve body assembly in position. • Secure the new gasket to the valve body cover with oil. | | NOTE: Installation position of the downshift lever between the stop and the downshift valve | 1. Place the valve body on the transmission. 2. Insert the selector lever linkage in the manual selector slide. | | | 95. Align the valve body with the transmission. | | | 96. Secure the valve body assembly. | | NOTE: The bolts are of different lengths. | 1. Tighten the single M6x30 bolt to the specified torque. 2. Tighten the two M6x35 bolts to the specified torque. | | | 97. Secure the valve body assembly (continued). 1. Tighten the four M6x45 bolts to the specified torque. 2. Do not fit the oil strainer retaining bolt (M6x45). | | | 98. Secure the valve body assembly (continued). • Tighten the 15 M6x40 bolts to the specified torque. • Remove the guide pins and tighten the M6x40 bolts to the specified torque. | | | 99. Install the selector lock mechanism spring. | Measure rear servo piston rod | | | | NOTE: If the transmission housing, servo piston or rear brake band has been renewed, the length of the rear servo piston rod must be measured. | 100. Fit the rear servo piston with any piston rod. | | | 101. Fit the special tool. 1. Fit the gasket. 2. Unscrew the adjusting bolt. | | NOTE: The measuring slot is above one of the three stop studs. | 3. Fit the special tool. | | | | | NOTE: Do not exceed the tightening torque. | 102. Tighten the adjusting bolt. | | | 103. Measure the piston stroke. • Set up the dial indicator. • Position the dial indicator plunger on the stop stud in the servo piston. • Zero the dial indicator. | | | 104. Measure the piston stroke (continued). • Unscrew the adjusting bolt completely whilst observing the dial indicator. • Permissible piston stroke: 3,0 ‐ 4,5 mm • If the reading is too low, fit a shorter piston rod. • If the reading is too high, fit a longer piston rod. | | | 105. Remove the rear servo piston. 106. Remove the piston rod. • Detach the circlip. • Withdraw the piston rod. | | | 107. Select the piston rod. • Piston rods are available in three different lengths, identifiable by the number of grooves: 1 groove: l = 88,05 mm 2 grooves: l = 84,65 mm no groove: l = 86,35 mm 108. Fit the piston rod. | | | 109. Fit the rear servo piston. 1. Fit the new seal. 2. Fit the servo piston. 3. Fit the servo cover and gasket. • Check again that the brake band is sitting correctly. | | | 110. Fit the oil strainer. | | | 111. Fit the sump. Use new bolts and a new gasket. 112. Detach the transmission from the assembly stand. | | | 113. Fit the start inhibitor switch. | | | 114. Install the solenoid switch. | | NOTE: See the Vehicle System Test Manual for adjustment instructions. | 1. Hook the kick down cable in place. 2. Install the solenoid switch. | | | | | NOTE: The larger shaft diameter points in the direction of travel. | 115. Fit the input shaft. | | | 116. Fit the torque converter. The torque converter hub must engage fully with the oil pump drive gear. | | | 117. Check the torque converter installation position: • Dimension ”A" between the converter housing flange and the converter locating stub: 9 mm (Transit with DOHC engine) 21 mm (Transit with 2,5 diesel engine) | |
