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Home >> BMW >> 1997 >> 850Ci >> Repair and Diagnosis (Single Page) >> Transmission >> Automatic Trans >> Diagnosis & Overhaul - ZF 5HP 30-E >> Component Disassembly & Reassembly >> "D", "E1", "E2" Brake & 2ND Gear Free-Wheel >> Reassembly

"D", "E1", "E2" Brake & 2ND Gear Free-Wheel: Reassembly

  1. Install "O" ring on planetary drive assembly. See REASSEMBLY  under PLANETARY DRIVE ASSEMBLY. Press brake clutch "E2" carrier onto planetary drive assembly. Assemble 2nd gear free-wheel by inserting cover disc, free-wheel cage with collar facing down, and second cover disc into outer free-wheel race. While holding 2nd gear free-wheel outer race, rotate and install inner 2nd gear free-wheel race. Install thrust washer, retaining disc and snap ring.
  2. Press 2nd gear free-wheel onto planetary drive assembly. Install needle bearing and thrust washer. See Figure . Install 2 "O" rings on bushing and press bushing into cylinder "D-E". Secure bushing with snap ring. Apply petroleum jelly to brake clutch "E1" piston sealing lips and press into cylinder "D-E". Install spring plate and using appropriate spring compressor, press down spring plate. Install split retaining ring. Remove spring compressor.
  3. Install clutch pack "E1". Install .12" (3.2 mm) thick snap ring. Check brake clutch "E1" clearance. Clutch "E1" (5-friction discs) clearance should be .063-.075" (1.60-1.90 mm). If clearance is not within specification, replace selective snap ring. Snap ring thicknesses are not available from manufacturer.
  4. Install new "O" rings onto brake clutch "E2" piston. Apply petroleum jelly to brake clutch "E2" piston and press into cylinder "D-E". Install spring plate and retaining ring. Using appropriate spring compressor, press down spring plate. Install snap ring. Install clutch pack "E2". Check brake clutch "E2" clearance. Clutch "E2" (4-friction discs) clearance should be .051-.063" (1.30-1.60 mm). If clearance is not within specification, replace selective snap ring. Snap ring thicknesses are not available from manufacturer.
  5. Turn cylinder "D-E" over. Install "O" ring on cylinder hub. Apply petroleum jelly to "O" ring and sealing surfaces of brake clutch "D" piston. Install brake clutch "D" piston. Install spring plate. Using appropriate spring compressor, press down spring plate and install split retaining ring. Install clutch pack "D".
  6. Check brake clutch "D" clearance. Clutch "D" (5-friction discs) clearance should be .063-.075" (1.60-1.90 mm). If clearance is not within specification, replace selective snap ring. Snap ring thicknesses are not available from manufacturer. Install cylinder "D-E" onto planetary drive assembly while rotating cylinder "D-E" to engage clutch pack splines. Measure height from end of shaft to top of brake clutch bushing. Height should be about 1.77" (45 mm).
  7. Attach Lifting Fixture (24 1 260) to cylinder "D-E"/planetary drive assembly. With bellhousing facing up, lower assembly into housing. Ensure that cylinder "D-E" does not catch on transmission case. Install 3 Torx-head bolts through transmission case web to brake clutch assembly only 2 turns. Tighten middle bolt to 22 ft. lbs. (30 N.m), then to 44 ft. lbs. (60 N.m). Tighten outer bolts to 11 ft. lbs. (15 N.m), then to 22 ft. lbs. (30 N.m), then to 46 ft. lbs. (63 N.m).
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