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Home >> Porsche >> 1985 >> 944 Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul - 087, 087E & 089 >> Transaxle Reassembly >> Input Shaft End

Input Shaft End

  1. Lubricate 1st-reverse brake piston with ATF. Install brake piston on oil pump. Install oil pump and piston assembly in case. Position pump with thin rib on pump body toward top of case. Install thrust washer on pump face.
  2. Install 1st-reverse brake shell into transmission case with lug engaged in groove at top of case. See Figure . Install 1st-reverse brake piston return springs on spring plate. Insert assembly into case with springs downward. Install attaching bolts and tighten in diagonal pattern.
    3. NOTE: After spring plate installation, insert pump shaft into oil pump and ensure gears turn freely. If not, remove oil pump and make sure it is assembled properly.
  3. Lubricate 2nd gear brake servo cover "O" rings. Install servo cover in case and install retaining snap ring. Rotate transmission so servo cover faces down.
  4. Position 2nd gear brake band in case and ensure it engages servo piston pin. Loosely install push rod for adjusting screw. Install adjusting screw and lock nut. Place 2 thrust washers and thrust bearing in position on end of oil pump and hold in place with grease.
  5. Install forward clutch into direct-reverse clutch, ensure splines on forward clutch drum fully engage splines in direct-reverse clutch lined plates. Turn transmission case with open end pointing downward. Lubricate and install direct-reverse and forward clutch assemblies as a unit.
  6. Slide clutch assembly unit onto oil pump neck and into 2nd gear brake band. Tighten 2nd gear brake band adjusting screw enough to prevent band from shifting its position on direct-reverse clutch drum. Rotate transmission case so open end is up.
  7. Install forward planetary-to-forward clutch needle bearing into forward clutch. Needle bearing is installed with smaller inside diameter toward forward planetary gear.
  8. Install forward planetary gear set into forward planetary ring gear in forward clutch. Install sun gear (short end first) into gear set. Install driving shell and thrust washer over sun gear. Install thrust washers on underside of reverse planetary gear set and hold in place with grease.
  9. Install gear set into case and onto sun gear. Install 1st-reverse brake waved washer into case. Install 1st-reverse brake plates into case, starting with steel (externally splined) brake plate. Alternate lined and steel plates until all are installed. See 1ST-REVERSE BRAKE PLATE  table.
    NOTE: New lined clutch and plates must be soaked in ATF for 15 minutes before installing. Manufacturer states that new valve body must be used with new 1st/Reverse lined plates.
  10. Install 1st gear one-way clutch assembly into transmission case. Insert retaining key between case and one-way clutch. Push clutch downward while rotating reverse planetary gear set to fully engage parts.
    NOTE: With one-way clutch installed, it should not be possible to rotate reverse planetary gear set counterclockwise due to locking of one-way clutch.
  11. Install one-way clutch-to-case snap ring. See Fig 1 . Snap ring opening must be opposite retaining key. If all parts are correctly installed, one-way clutch snap ring groove will be exposed. Do not force snap ring into groove of incorrectly assembled unit.
  12. Position thrust washer and needle bearing on rear side of reverse planetary gear set. Larger inside diameter collar faces toward reverse planetary gear set. Install reverse planetary ring gear into case. It must fully engage reverse planetary gear set.
  13. Install new separation plate gasket over case studs and place separation plate over gasket. Install and tighten retaining screws.
    Fig 1: Installing One-Way Clutch Snap Ring
    G00153646Courtesy of VOLKSWAGEN UNITED STATES, INC.
    NOTE: Second gear brake band must be adjusted at this time. Transaxle must be horizontal during adjustment to prevent band from jamming.
  14. Tighten brake band adjusting screw to 87 INCH lbs. (10 N.m). Loosen screw. Retighten to 43 INCH lbs. (5 N.m). Back off adjusting screw exactly 2 1/2 turns on 089 models and on 087 models in 5000S model vehicles. Back off adjusting screw exactly 2 turns on all other 087 models. Tighten adjusting screw lock nut.
  15. If case linkage was disassembled, reinstall in case. Install accumulator piston with seal lip pointing toward case. Install accumulator piston spring in piston.
  16. Install valve body assembly into case, ensuring manual valve engages manual lever and kickdown valve engages kickdown lever. Install bolts attaching valve body to case. Tighten from center outward.
  17. Position new pan gasket on transmission case. Install oil pan and tighten oil pan bolts.
NOTE: See FINAL DRIVE  for installation of turbine and pump shafts and for measurement of end play between transmission and final drive.
1ST-REVERSE BRAKE PLATE

Application Steel Plates Lined Plates
087 Series 5 5
089 Series 4 4
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