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Home >> Porsche >> 1985 >> 944 Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul - A/T - AUDI 087, 087E, 089 >> Transmission 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 into case. Position pump so thin rib on pump body is toward top of case, install thrust washer on pump face.
  2. Install 1st/reverse brake shell into transmission case so lug engages in groove at top of case. 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. See Fig 2 .
    NOTE: After engine 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 serve 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 pushrod 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, making sure splines on forward clutch drum fully engage splines in Direct/Reverse clutch lined plates. Turn transmission case so open end points down at angle. Lubricate and install Direct/Reverse and forward clutch assemblies as unit.
    Fig 1: Exploded View of Band Servo Assembly
    G96I15055Courtesy of AUDI OF AMERICA, INC.
    Fig 2: Installing Brake Shell in Transmission Case
    G96J15056Courtesy of AUDI OF AMERICA, INC.
  6. Slide clutch assembly unit onto oil pump neck and into 2nd gear brake band. Tighten 2nd gear brake band adjusting screw just 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  .
    1ST/REVERSE BRAKE PLATE

    Application Steel Plates Lined Plates
    087 Models..... .....5..... .....5
    089 Models..... .....4..... .....4
    NOTE: New lined clutch plates must be soaked in ATF for 15 minutes before installing. Manufacturer states that new valve body must be used with new 1st/reversed 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. Snap ring opening must be opposite to 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 transmission.
  12. Position thrust washer and needle bearing on rear side of reverse planetary gear set. Larger inside diameter collar faces towered reverse planetary gear set. Install reverse planetary ring gear into case so it fully engages reverse planetary gear set.
  13. Install new separation plate gasket over case studs and place separation plate over gasket. Install and tighten retaining screws.
    NOTE: Second gear brake band must be adjusted at this time. Transmission case 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 found in 5000 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. See Figure . Install accumulator piston with seal lip pointing toward case. Install accumulator piston spring in piston.
  16. Install valve body assembly into case, making sure manual valve engages manual lever and kickdown valve engages kickdown lever. Install valve body-to-case bolts and tighten from center outward.
  17. Position new pan gasket on transmission case. Install oil pan and tighten oil pan bolts.
NOTE: See FINAL DRIVE ASSEMBLY for installation of turbine and pump shaft and measurement of play between transmission and final drive.
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