Vauxhall Workshop Service and Repair Manuals

Survey of Assemblies, AR 25/35

Illustration shows torque converter for 4- and 6-cylinder petrol engines.

Survey of Assemblies, AR 25/35 (Continued)

Survey of Assemblies, AR 25/35 (Continued)

Survey of Assemblies, AR 25/35 (Continued)

Survey of Assemblies, AR 25/35 (Continued)

Survey of Assemblies, AR 25/35 (Continued)

Survey of Assemblies, AR 25/35 (Continued)

Automatic transmission AR 25/35, parking lock and selector lever position switch

Converter contains a large amount of transmission fluid.

Transmission fluid escapes. Place collecting basin underneath.

  Remove

Remove converter with KM-574 (1) or KM-899 (vehicles with diesel engine) from converter housing.

  Install

Attach KM-113-A (3) in conjunction with KM-113-5 (2) to transmission.

Attach assemblies to KM-113-2.

Install short arm of KM-113-5 towards output side, so that vent line (arrow) remains free.

Do not press too heavily on transmission holder (1), since otherwise the assemblies cannot be removed – the transmission housing would be deformed.

  Remove

Remove fastening nut for output flange (socket A/F 30, extra long), counterhold with KM-623 (2).

Detach output flange (3) from the output shaft. If stiff, detach with KM-628-A.

  Inspect

Check O-ring of output flange for wear and damage, replace if necessary.

Turn transmission carefully with KM-113-A (4), so that any dirt present (shavings) cannot fall into the valve body.

  Remove

Converter housing points upwards.

Drain remaining transmission fluid through extension (arrow).

Remove heat shield (3) for selector lever position switch (3 fastening bolts).

Remove selector intermediate lever (1) from the transmission selector lever shaft (2) (1 fastening nut).

Detach selector lever position switch with shield (5) and wiring harness (6) from the transmission selector lever shaft (2 fastening bolts).

Detach transmission output speed sensor (2) from transmission extension (1) (1 fastening bolt).

  Inspect

Replace O-ring (3) in transmission output speed sensor.

  Remove

Turn transmission – transmission fluid pans point upwards. Detach transmission fluid pan (4) and gasket (5) from transmission main casing (6) (16 fastening bolts).

  Clean

Remove fixing magnet (7) from the transmission fluid pan. Clean inside of transmission fluid pan, transmission fluid pan sealing surfaces and fixing magnet.

Detach transmission fluid pan (1) and gasket (2) from transmission intermediate casing (3) (12 fastening bolts).

  Clean

Clean transmission fluid pan sealing surface and inside of transmission fluid pan.

  Remove

Detach fluid screen (5) with stuck-on gasket (4) (3 fastening bolts).

Remove fastening bolts (1) and remove detent spring (2).

Caution

Do not pull on wiring harness.

  Remove

Carefully release 7-pin wiring harness plug (1) for solenoid valves from transmission housing connection plug with small screwdriver and disconnect.

Do not pull on the cables of the wiring harness.

  Remove

Detach plug connection at solenoid valve (2) for brake band servo.

Detach plug connection at solenoid valve (4) for 1/2 shifting and 3/4 shifting.

Detach plug connection at solenoid valve (1) for 2/3 shifting.

Remove wiring harness (3) for main casing valve body.

Detach brake band servo cover (1) and gasket (2) (4 fastening bolts).

Detach fastening bolts (arrows) for valve body assembly (3).

Lift valve body assembly and detach control lever (2) for shift valve (3) on shift segment (1).

Remove valve body assembly with intermediate plate and gasket. Do not reuse gasket.

Remove shift valve (2) with control lever (1) from valve body assembly.

Note position of control lever (1). Long end points towards selector valve (2).

Do not lose valve balls.

To remove, do not use any magnets because the valve balls will become magnetic and will attract any resulting shavings, which may lead to leaks in the fluid circuit in question or to malfunctions.

  Remove

Remove valve balls (1) from the fluid ducts of the transmission main casing.

Do not pull on the cables of the wiring harness.

  Remove

Detach plug connection at solenoid valve for pressure regulator (1).

Detach plug connection at solenoid valve for converter clutch (2).

Detach wiring harness plug (5) from connection plug (4) on intermediate casing.

Remove wiring harness for intermediate casing valve body (6).

If present (L 5620 I), pull out sheathed part of wiring harness until wiring harness plug for pressure regulator solenoid valve (7) can be removed past the retaining lug (8).

Detach fastening bolts (arrows) for valve body assembly (1) from intermediate casing.

Detach valve body assembly with support plate (2) and both gaskets beneath.

Caution

Do not lose valve ball.

To remove, do not use any magnets because the valve ball will become magnetic and will attract any resulting shavings, which may lead to leaks in the fluid circuit in question or to malfunctions.

  Remove

Remove valve body (3) from the fluid duct of the transmission intermediate casing.

Remove servo piston assembly (2).

Attach KM-J-23075-A (1) to transmission casing. KM-J-23075-A has a symmetrical design, attach in the position shown.

Compress relief spring for brake band servo piston with spring compressor. Slowly relieve tension on KM-J-23075-A (high spring tension) and remove.

Remove retaining ring (3) and remove servo piston assembly.

  Inspect

Check servo piston assembly for wear and damage, replace with new parts, if necessary.

Detach fastening bolts (arrows) and wiring harness bracket (1, 2 and 3) if fitted.

Detach transmission extension (4) with gasket below from transmission casing.

Remove pawl (6) for parking lock with retaining spring (7) from transmission extension.

  Inspect

Check liner (5), pawl and retaining spring for wear and damage, replace if necessary.

Detach pulse pickup (1) for output speed sensor from the output shaft (2).

Detach parking lock gear (3) from output shaft using screwdriver.

Check parking lock gear for wear and damage.

Check hook seal ring (1) on hub of parking lock gear for breakage and wear, replace if necessary.

  Remove

Clamp vent pipe (2) with pliers and remove from transmission casing. Avoid damage.

Remove fluid reservoir (4). Installation position is determined by the guide (3).

Attach KM-686-1 (2) and KM-469-14 (3) to the intermediate casing to remove the 3/4 accumulator piston. The short side of remover bridge points to the converter housing.

Compress accumulator spring with KM-469-14 (3) until the retaining ring is free. Remove retaining ring (1) – do not damage ring groove in the process.

Relieve tension on KM-686-1 and detach.

Remove closure cap (7) for the accumulator piston with KM-686-2 (5) in conjunction with KM-838 (6) and KM-J-7004 (4).

Prevent tilting of the closure cap by aligning the tools at an angle.

Release closure cap with light taps of a soft metal drift and plastic hammer.

Remove closure cap (1) and spring (2) for accumulator piston.

Remove pin using suitable pliers.

Remove piston for 3/4 accumulator using pliers.

Doing this, do not tilt piston.

For further disassembly, turn transmission in adapter by 90° (converter housing upwards).

Release cover of seal ring for fluid pump (3 fastening bolts).

Drive seal ring out of converter housing with KM-J-23129 or KM-586 (1) in conjunction with KM-J-7004 (2).

If seal ring is difficult to remove, remove after removal of converter housing.

Detach fastening bolts for converter housing (outer screw circle – 7 fastening bolts).

Detach fastening bolts for fluid pump (inner screw circle – 5 fastening bolts).

Detach converter housing from intermediate casing by gently turning back and forth, as well as from drive shaft and fluid pump shaft (1).

Note:   Operation is only necessary if seal ring in converter housing could not be removed using KM-J-23129 or KM-586.

  Remove

Drive out seal ring from converter housing using suitable screwdriver.

Detach seal ring (1) from intermediate casing. Seal ring is not re-used.

Lift support plate (2) off fluid pump and remove.

Detach O-ring (2) from drive shaft (1). O-ring is not re-used.

Remove fluid pump (3) from intermediate casing (5).

Detach gasket (arrow) from fluid pump. Gasket is not re-used.

Remove thrust washer (4, optional).

Remove thrust ring (1) for 4th gear clutch and overrunning clutch assembly with clutch discs from intermediate casing.

Detach clutch discs.

Steel plates: x 4.

Lining plates: x 2.

One steel plate remains in the casing, remove this as well.

Caution

If clutch plates are not being replaced, install in original position. See also "Technical Data" for number of steel and lining plates.

Remove hollow gear from the intermediate casing.

Remove thrust washer (1) from intermediate casing (2).

Remove intermediate casing (1) with piston for 4th gear clutch, centre support and piston for reverse clutch from transmission casing (2).

Place KM-680-A (3) on spring set seat (5) in intermediate casing.

Insert KM-J-23078-A (4) through KM-680-A and the bore hole in the intermediate casing so that the thread piece protrudes at rear.

Position sleeve of KM-J-23078-A (1) at centre support hub (2) and compress KM-J-23078-A using fastening nut (3) until retaining ring for spring set seat is free.

Remove retaining ring out of ring groove using suitable screwdriver.

Relieve tension on KM-J-23078-A and detach. Detach KM-680-A.

Detach retaining ring (5) and spring set seat (4) with relief springs from clutch piston (6).

Note:   Relief springs can only be replaced in assembly with spring set seat.

Optionally detach thrust washer (2) from centre support hub (3).

Detach gasket (1) and seal ring (4) from intermediate casing. Gasket and seal ring are not re-used.

Attach KM-J-23078-A to the reverse clutch.

Attach sleeve (5) at the inside of the intermediate casing to the clutch piston.

Compress the relief springs using the fastening nut (6) until the retaining ring is free on the rear of the intermediate casing.

Turn intermediate housing upside down.

Remove retaining ring (2) from the groove with KM-396.

Relieve tension on KM-J-23078-A (1) and detach.

Detach retaining ring (5).

Detach seat (3) for relief springs and 24 relief springs from reverse clutch.

Remove clutch piston (4) from intermediate housing.

Detach 8 fastening bolts (arrows) for centre support.

Remove centre support (1), gasket (2), support plate (3) and gasket underneath support plate. Do not reuse gaskets.

Note:   Corresponding installation position is predetermined by bore holes. Support plate and gaskets are available as a set.

Remove throttle (1) from the bore (2) in the intermediate casing. Inspect throttle, replace if necessary.

Remove clutch piston for 4th gear clutch out of intermediate casing with pliers and lever.

Replace inner and outer seal ring on piston for reverse gear clutch and 4th gear clutch. Sealing lip of seal rings always points towards piston crown.

Remove assembly of 2nd and 3rd gear clutch (2) with clutch discs (arrows) for the reverse gear from the transmission casing (1).

Detach clutch discs from assembly (3).

Damping cushion: x 1 (5)

Steel plates: x 5 (4)

Lining plates: x 4.

If clutch plates are not being replaced, install in original position. See also "Technical Data" for number of steel and lining plates.

Detach the freed axial needle bearing (1) with washer (2) from 2nd and 3rd gear clutch assembly.

Caution

Note installation position of bearing.

  Remove

Remove thrust ring (3) for reverse clutch from the transmission casing.

Remove planetary carrier (1) from the transmission casing.

  Inspect

Check the axial needle bearing (3) and the radial needle bearing (2) of the planetary carrier. The needle bearings are fitted securely on the output shaft, if defective the planetary carrier must be replaced.

Remove brake band drum (1) with rear sun gear (2) from transmission housing.

Detach rear sun gear (2) from brake band drum (1).

Detach brake band at retaining lug and remove from transmission casing.

Remove freed bearing (one-piece axial needle bearing with thrust washer) from transmission casing.

Note installation position of bearing. This bearing may have remained on the output side of the brake band drum.

Note:   If transmission selector lever shaft or seal ring for transmission selector lever shaft are damaged:

  Remove

In the transmission casing, detach fastening nut from the transmission selector lever shaft.

If necessary, remove actuating rod for parking lock.

Remove roll pin using pliers.

For this purpose, insert nail (1) with suitable diameter into roll pin, so that the latter is not sheared off when being pulled out.

Use sheet metal (2) as pad to avoid damage to sealing surface of transmission housing.

Install transmission selector lever shaft. If removed: connect actuating rod for parking lock.

Insert transmission selector lever shaft, note installation position (groove for roll pin).

Drive in new roll pin only so far that later removal remains possible – transmission selector lever shaft must be free to move.

Torque

Fastening nut to shift segment – 22 Nm / 16 lbf. ft.

Remove connection plug (1) on main casing and connection plug (2) on intermediate casing by pressing back the lugs (arrows) with a screwdriver.

  Inspect

Check O-rings and connection plugs for damage, replace if necessary.

  Install

Reinstall both connecting plugs without damaging O-rings.

Caution

On replacing the connecting plug on the main housing – see operation "Adapter Piece at Main Housing, Replace".

Install brake band in transmission casing.

Install brake band, so that valve lifter of the brake band servo piston can be installed for proper functioning.

Install bearing (one-piece axial needle bearing with thrust washer).

Housing sleeve serves as guide for thrust washer and bearing.

Install sun gear (2) into brake band drum (1).

Install brake band drum (1) with sun gear (2) in transmission casing.

Note:   Before further assembly, turn transmission in adapter by 90°.

  Assemble

Insert KM-689 (1) into transmission casing.

Insert relief spring for servo piston.

Insert servo piston assembly (1) and retaining ring into KM-689.

Caution

If necessary, rework supports of KM-J-23075-A (3) at points marked with arrows, so that these can be moved over KM-689 (2).

  Assemble

KM-J-23075-A has an asymmetrical design. Attach KM-J-23075-A in the position shown on transmission casing. Compress relief spring for brake band servo piston with KM-J-23075-A until ring groove is free.

Install retaining ring. Ensure it is correctly seated.

Relieve tension on KM-J-23075-A (1) and detach.

Detach KM-689 (2).

  Adjust

Adjust brake band: Release lock nut (5) at adjustment bolt. Tighten adjustment bolt with MKM-111 (3) and MKM-J-6459-B (4) to the prescribed torque of 5 Nm / 4 lbf. ft.

Hold sleeve and turn adjusting screw back 5 turns.

Remove insert and torque wrench.

Tighten lock nut with sleeve held in position – tightening torque 20 Nm / 15 lbf. ft.

Check axial needle bearing (2) and radial needle bearing (1) in the planetary carrier for damage or wear.

Caution

On installation, do not let planetary carrier fall into sun gear of brake band drum, since these bearings can be damaged.

Before inserting planetary carrier align markings on planetary gears to markings on planetary carrier.

  Assemble

Install planetary carrier carefully in transmission casing.

Place axial needle bearing (3) with washer (2) (note installation position) onto input sun gear (1) of 3rd gear clutch.

In order to fix, adhere bearing and washer with installation grease.

Install 2nd and 3rd gear clutch assembly (1) into transmission housing.

Caution

If any components are defective, use complete set with lining and steel plates and thrust ring.

Insert thrust ring (2) for reverse clutch with collar side outwards. Alternately insert steel plates (4) and lining plates (3). Insert damping cushion (5).

Installation height of 2nd gear clutch relative to transmission housing:

• Attach KM-J-23085-A to flange of transmission casing.
• Loosen locking screw and install inner shaft on clutch hub contact surface.
• Tighten locking screw and remove Measuring Gauge KM-J-23085-A.

Remove dimension "I" (illustration H 0176) at the measurement gauge (1) and select the relevant thrust washer. The relevant washers are available via the "Aftersales" division.

Do not exceed dimension "I" with selected pressure plate, i.e. preferably use the next smaller plate.

  Assemble

Install clutch piston for 4th gear using KM-680-A (1) to hold down spring set and using KM-837 (2) and KM-684 (3) to protect piston seal rings.

Insert clutch piston (1) for 4th gear clutch into KM-684 (2).

Slide KM-684 and KM-837 onto the clutch piston to protect the outer and inner seal ring.

Coat sealing lips of sealing rings with transmission fluid or installation grease.

Install clutch piston with KM-680-A in intermediate casing.

Remove KM-684 and KM-837.

Install throttle (3) in bore (4) in intermediate casing. Place lug of throttle in the fluid duct.

Attach KM-678 (3) to intermediate casing (2). Place support plate (1) on intermediate casing with one gasket on each side.

Note:   Support plate and gaskets are available as a set. Installation position is determined by bore holes.

  Inspect

Check seal rings on hub of centre support for wear and lateral play, replace if necessary.

  Assemble

Attach centre support (4) loosely to intermediate casing (6 fastening bolts). Installation position is determined by the hole pattern.

Detach KM-678, insert the remaining fastening bolts.

Tighten all fastening bolts – tightening torque 23 Nm / 17 lbf. ft.

Install clutch piston (2) of reverse clutch in conjunction with Protective Sleeve KM-233-A (1) in the centre support.

Caution

Coat sealing lips of seal rings with transmission fluid or installation grease.

Remove Protective Sleeve KM-233-A.

  Assemble

Install relief springs (x 24) in clutch piston (4).

Carefully insert intermediate ring (3) for release springs and retaining ring (5) so that release springs are correctly positioned.

Attach KM-J-23087-A (3) to the reverse clutch.

Place sleeve (2) inside intermediate housing on clutch piston.

Compress relief springs with fastening nut (1) until the groove for retaining ring on the rear of the intermediate casing is free.

Turn intermediate housing.

Install retaining ring (4) with KM-396 in groove.

Relieve tension on KM-J-23087-A and detach.

Coat selected thrust washer (3) with installation grease and slide on hub (4) of centre support.

Attach seal ring (1).

Attach gasket (2) – installation position is determined by the hole pattern.

Place spring set seat with relief springs (5) onto clutch piston (7).

Insert retaining ring (6).

Place KM-680-A (1) on the spring set seat (3) in intermediate casing.

Guide KM-J-23078 (2) through KM-680-A and bore hole in intermediate casing, so that threaded piece protrudes at rear.

Attach sleeve of KM-J-23078-A (6) to hub of centre support (4) and compress KM-J-23078-A using fastening nut (5), so that the groove for the retaining ring of the spring set seat is free.

Install retaining ring in ring groove with suitable screwdriver.

Relieve tension on KM-J-23078-A and detach. Remove KM-680-A.

Install new O-rings (2) in transmission casing.

Install KM-675 (1) in bore holes shown in transmission casing.

Caution

Leave KM-675 installed until converter housing is fitted.

Assemble intermediate casing (3) and transmission casing (4).

Caution

Carefully slide intermediate casing onto KM-675 so as not to damage the gasket.

Measure axial play of drive shaft:

Slide KM-681-1 (3) over KM-675.

Attach KM-681-1 on intermediate casing with three fastening bolts.

Position KM-681-2 (4) on drive shaft.

Position KM-238-2 (2) in conjunction with MKM-571-B (1) on intermediate casing with corresponding pin as extension and set dial gauge to "zero".

Manually load drive shaft axially at housing output in both directions. Read off play from gauge.

Play must be between 0.36 mm (0.014") and 0.79 mm (0.031").

Install thrust washer (1) with guide tabs in corresponding recesses in the clutch piston for 4th gear.

If thrust bearing (2) was removed, ensure it is properly seated – note installation position.

  Assemble

Install hollow gear (1) and overrunning clutch assembly (3) in the intermediate casing.

Install overrunning clutch assembly into intermediate housing by turning slightly.

The lining plates must be laid in transmission fluid for about 20 minutes prior to installation.

Installation position of clutch discs and of thrust ring is determined by guide lugs.

  Assemble

Alternately install steel plates (1) and lining plates in the intermediate casing.

Insert thrust ring (2) with recess (3) outwards.

Attach KM-J-23085-A (4) to flange of intermediate casing.

Loosen locking screw and install inner shaft on clutch hub contact surface.

Tighten locking screw and remove Measuring Gauge KM-J-23085-A.

Remove dimension "I" (Illustration H 0183) at the measurement gauge (1) and select the relevant thrust washer. The relevant thrust washers are available via the "Aftersales" division.

Do not exceed dimension "I" with the selected thrust washer, i.e. preferably use next smaller sized washer.

  Install

Install seal ring for the fluid pump in converter housing. Attach KM-613-1 (3) and KM-J-28540 (2) and drive seal ring into converter housing.

After installation, secure seal ring with three fastening bolts (1).

Install support plate (1) onto fluid pump.

Installation position of support plate (1) is determined by bore holes (arrows).

Place converter housing (2) on fluid pump. Installation position of converter housing is determined by hole pattern of outer bolt circle.

Insert KM-676 (1) into outer screw circle for locking. Install 5 fastening bolts of the inner screw circle and loosely tighten.

Fit KM-692 (3) up to stop on fluid pump shaft – outer part fits into fluid pump seal ring.

Hold lower tommy bar, manually tighten upper tommy bar (arrow).

This centralises the fluid pump with respect to the converter housing.

Torque

Tighten 5 inner fastening bolts for fluid pump at converter housing alternating crosswise – 20 Nm / 15 lbf. ft.

Release KM-692 at upper toggle and remove. Remove KM-676.

Coat selected thrust washer (1) with installation grease and attach to fluid pump hub – note installation position.

Attach gasket (2) – installation position is determined by the hole pattern.

Attach seal ring (3) to converter housing (arrow).

Caution

Avoid damaging the gasket with KM-675 (5).

  Assemble

Carefully attach converter housing (4) on intermediate casing (6) with fluid pump installed.

Insert 5 fastening bolts on outer screw circle and tighten slightly. Detach KM-675, insert remaining 2 fastening bolts and tighten slightly.

  Measure

Measure final axial play: Slide KM-682 (4) onto drive shaft and tighten locking bolt.

Position KM-238-2 (2) in conjunction with MKM-571-B (1) and corresponding pin as extension on converter housing and place probe of dial gauge on face of drive shaft.

Caution

Pull drive shaft (3) with KM-682 upwards until point of contact is noticeable. Set dial gauge to "zero". Then continue to turn drive shaft upwards and read off the play on the dial gauge. Play must be between 0.10 mm (0.004") and 0.69 mm (0.027").

Detach MKM-571-B, KM-238-2 and KM-682.

  Assemble

Install new O-ring (1) on drive shaft.

Replace O-ring (2) of 3/4 accumulator piston.

Slide 3/4 accumulator piston into KM-685 (1) to protect O-ring.

To do this, coat O-ring with transmission fluid or installation grease.

For further assembly, turn transmission in adapter by 90°.

Insert accumulator piston in conjunction with KM-685 into transmission casing.

Install accumulator piston with suitable pipe (3).

Remove KM-685.

Insert pin (2) and spring (1).

Install new seal cap (3) for accumulator piston.

Attach KM-686-1 (2) to the intermediate casing. The short side of bridge points to the converter housing. Compress accumulator spring with KM-469-14 (3) until the ring groove is free. Install retaining ring (1). Ensure correct seating – press into ring groove with screwdriver if necessary. Relieve tension on KM-686-1 and detach with KM-469-14 (3).

Before further assembly, turn transmission in adapter by 90°.

  Assemble

Fit fluid reservoir (3) in the transmission casing. Installation position is determined by the guide (2). Insert vent pipe (1) in bore in transmission casing and fluid reservoir.

Slide parking lock gear (5) onto output shaft.

Install pulse pickup (6) of output speed sensor onto output shaft.

Attach new gasket (4) onto transmission casing.

Check seal ring (2), radial needle bearing (1) and liner (3) in the extension for damage and wear, replace with new parts if necessary.

Only required when replacing: Remove seal ring using KM-J-7004 in conjunction with KM-586.

  Assemble

Install retaining spring (5) with angled end towards pawl and pawl (4) for parking lock gear in transmission extension.

Actuation rod (2) for parking lock must slide in the liner.

  Assemble

Position transmission extension (1) onto transmission casing.

If fitted – attach bracket for wiring harnesses (3, 4 and 5) with fastening bolts (arrows) crosswise.

Torque

Transmission nose piece to transmission housing – 32 Nm / 23.5 lbf. ft.

Install new seal ring with KM-629-1 (1) in transmission extension.

Insert valve ball (1) into the fluid duct of the intermediate casing. Secure with installation grease.

Caution

The installation sequence must be observed. Gasket (2) is provided with a slot. Gasket (4) is provided with 2 bores at the corresponding location.

  Assemble

Place gasket (2), support plate (3) and gasket (4) onto valve body (5) of intermediate casing.

Place valve body assembly with gaskets and support plate (1) onto intermediate casing. Insert 7 fastening bolts.

Torque

Valve body to intermediate housing – 20 Nm / 15 lbf. ft.

Route wiring harness at the plug connection for pressure regulator solenoid valve (1) under the retaining lug (2).

Connect wiring harness plug to pressure regulator solenoid valves (1) and converter clutch (3).

Insert connecting plug into intermediate housing (5).

Restore plug connection (4 and 5) on the intermediate casing.

Insert 2 valve balls into fluid ducts (arrows) of transmission housing.

Caution

Use installation grease for fixing.

  Assemble

Attach KM-678 (2) to transmission casing.

Put gasket (1) onto transmission housing.

Place valve body (1) over KM-678 (2) onto transmission casing.

Caution

Long end of control lever points towards shift valve.

  Assemble

Attach shift valve (5) with control lever (3) in valve body assembly.

Attach control lever to shift segment (4).

Attach 7 fastening bolts (arrows) – tightening torque 20 Nm / 15 lbf. ft.

Detach KM-678 (1 and 2).

Insert main housing connection plug – insert new additional support O-ring in dedicated groove.

Insert 7-pin wiring harness plug (4) at connection plug on transmission. Route wiring harness for solenoid valves correctly through indentations of the valve body to prevent damage when bolting on fluid screen.

Attach detent spring (3) to transmission with fastening bolts (arrows) – tightening torque 20 Nm / 15 lbf. ft.

Place wiring harness (2) on valve body assembly (4).

Attach wiring harness plug to solenoid valve for 1/2 and 3/4 shift (5).

Attach wiring harness plug to solenoid valve for 2/3 shift (1).

Attach wiring harness plug to brake band servo solenoid valve (3).

Attach brake band servo cover (1) with new gasket (4 fastening bolts) – tightening torque 25 Nm / 18 lbf. ft.

Attach fluid screen (3) with stuck-on gasket (2) to valve body assembly (3 fastening bolts) – tightening torque 20 Nm / 15 lbf. ft.

Insert fastening bolts with locking compound, if not microencapsulated.

Torque

Attach fluid pan (1) with gasket (2) to intermediate casing (3) (12 fastening bolts) – tightening torque 12 Nm / 9 lbf. ft.

Caution

Insert fastening bolts with locking compound, if not microencapsulated.

Torque

Attach fluid pan (4) with gasket (5) and fixing magnet (7) on transmission casing (6) (16 fastening bolts) – tightening torque 12 Nm / 9 lbf. ft.

Attach output speed sensor to transmission extension (1 fastening bolt and washer) – tightening torque 12 Nm / 9 lbf. ft.

Push selector lever position switch with wiring harness (1) onto transmission selector lever shaft (2) and screw in 2 fastening bolts – only tighten after the adjustment.

  Adjust

Adjust selector lever position switch – see corresponding operation in this group.

Apply locking compound to the thread of the output shaft.

Attach output flange (2) to output shaft with fastening nut – tightening torque 100 Nm / 74 lbf. ft.

Note:   Use socket A/F 30, extra long and KM-623 (1) to counterhold.

  Assemble

Attach torque converter with KM-574 (3) to drive shaft.

Remove KM-574.

Detach transmission with KM-113-A (1) and KM-113-5 (2) from KM-113-2.

Detach KM-113-A and KM-113-5.

  Install

"Automatic Transmission, Remove and Install (Vehicles with 4-Cylinder Petrol Engine)", "Automatic Transmission, Remove and Install (Vehicles with V6 Engine)", "Automatic Transmission, Remove and Install (Vehicles with Diesel Engine)".