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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 >> Clutch "A", "B" & "C" >> Reassembly

Clutch "A", "B" & "C": Reassembly

  1. Install 2 NEW "O" rings onto bushing and press bushing into cylinder "A-C". See Figure . Install snap ring to secure bushing. Install 2 NEW "O" rings onto clutch "A" piston. Coat seals with petroleum jelly and press clutch "A" piston into cylinder "A-C". Install NEW "O" ring onto oil dam. Coat "O" ring with petroleum jelly and install spring plate and oil dam into cylinder "A-C". Using appropriate compressor, press oil dam and spring plate and install snap ring. Remove compressor.
  2. Install NEW "O" rings onto clutch "C" piston. Coat "O" rings with petroleum jelly and install clutch "C" piston into cylinder "A-C". Install spring plate and retaining ring. Using appropriate compressor, press spring plate and retaining ring. Install snap ring onto cylinder "A-C". Remove compressor.
  3. Install clutch pack "C", starting with spring disc. Install snap ring. Check clutch "C" clearance. Clutch "C" (3-friction discs) clearance should be .031-.047" (.80-1.20 mm). If clearance is not within specification, replace selective snap ring. Snap ring thicknesses are not available from manufacturer.
  4. Install clutch pack "A", starting with spring disc. Install snap ring. Check clutch "A" clearance. Clutch "A" (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.
  5. Remove snap ring and top clutch plate from clutch pack "A". Install clutch "C" carrier while rotating into cylinder "A-C". Install clutch "B" carrier into cylinder "A-C". Reinstall clutch "A" top clutch plate and snap ring. Install NEW "O" ring and 2 square cut seals onto input shaft. Apply petroleum jelly to "O" ring and seals and install input shaft into cylinder "A-C".
  6. Install bearing race and needle bearing onto hub of input shaft. Align clutch discs of clutch pack "A" and insert intermediate shaft. Install needle bearing and bearing race onto intermediate shaft.
  7. Install 3 NEW "O" rings onto clutch "B" piston and apply petroleum jelly onto "O" rings. Install square cut seals onto clutch "B" cylinder. Install clutch "B" piston into clutch "B" cylinder. Install spring plate and oil dam. Using appropriate spring compressor, press oil dam and spring plate. Install snap ring.
    8. NOTE: Clutch pack "B" may contain five or six friction discs.
  8. Install clutch pack "B". Install snap ring. Check clutch "B" clearance. See CLUTCH "B" CLEARANCE SPECIFICATIONS  table. If clearance is not within specification, replace selective snap ring. Snap ring thicknesses are not available from manufacturer.
    CLUTCH "B" CLEARANCE SPECIFICATIONS

    Number Of Friction Discs In. (mm)
    5 .063-.075 (1.60-1.90)
    6 .079-.091 (2.00-2.30)
  9. Align clutch discs on clutch pack "B" and install onto cylinder "A-C". Install needle bearing onto clutch "B" cylinder hub. Install square cut seals onto sun gear shaft. Apply petroleum jelly to seals and install sun gear shaft onto clutch "C" carrier. See Figure . Using Staking Tool (24 1 300), bend clutch "C" carrier tabs over sun gear shaft.
  10. With bellhousing assembly facing up, install needle bearing onto planetary carrier No. 2 shaft. Align clutch discs of clutch pack "D" with sun gear shaft splines. Install cylinder "A-C" with sun gear shaft facing down. Ensure that there is no pressure on clutch pack "D" with cylinder "A-C" installed.
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