Planetary gearbox, assembling

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Install axial needle bearing with washer onto input gear.

NOTE: The following list refers to items in Fig 1.

- Axial needle bearing washer
- Axial needle bearing
- Axial needle bearing washer
- Install smooth side into input gear
- Input gear
(Installed in transmission housing. See PLANETARY GEARBOX DISASSEMBLY AND ASSEMBLY, OVERVIEW .)

Fig 1: Installing Axial Needle Bearing With Washer Onto Input Gear

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Install O-ring in planet carrier.

Fig 2: Installing O-Ring In Planet Carrier

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NOTE: After replacing planet carrier, adjust. See PLANET CARRIER, ADJUSTING .

Install washer and axial needle bearing into planet carrier.

NOTE: The following list refers to items in Fig 3.

- Axial needle bearing
- Transmissions up to 12.92: outer diameter 41.0 mm (1.61 in.). See TRANSMISSIONS FOR VEHICLES WITH TRANSMISSION RANGE (TR) PROGRAM SWITCH -E122- .
- Transmissions from 01.93: outer diameter 39.1 mm (1.54 in.). See TRANSMISSIONS FOR VEHICLES WITH ELECTRONIC PROGRAM SWITCH IN TRANSMISSION CONTROL MODULE (TCM) .
- Axial needle bearing washer
- Small sun gear
- Cannot be removed for transmissions from 01.93. See TRANSMISSIONS FOR VEHICLES WITH ELECTRONIC PROGRAM SWITCH IN TRANSMISSION CONTROL MODULE (TCM) .
- Planet carrier

Fig 3: Installing Washer And Axial Needle Bearing Into Planet Carrier

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Install planet carrier into input gear.

Fig 4: Installing Planet Carrier Into Input Gear

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Center washer and axial needle bearing in small sun gear.
Install inner and outer -B1- plates.
Install pressure plate with flat side facing plates.

Thickness of pressure plate varies according to number of plates. See item 5 in III - Free wheel and reverse gear brake -B1-, removing and installing .

Install dished washer with convex side facing toward free wheel.

Fig 5: Installing Dished Washer

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NOTE: When replacing:

Transmission housing
Free wheel
Piston for reverse gear brake -B1-
or plates

Then adjust -B1-. See REVERSE GEAR BRAKE -B1-, ADJUSTING .

Preload free wheel rollers with 3267 assembly ring and install free wheel.

Fig 6: Preloading Free Wheel Rollers With Assembly Ring

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Install circlip -b- for free wheel and circlip -a- for supporting tube.
- Install so that circlip gaps are over free wheel retaining wedge (arrow).

Fig 7: Installing Circlips

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Carry out check measurement of -B1-. See REVERSE GEAR BRAKE -B1- CHECK MEASUREMENT .
Install washer with axial needle bearing in large sun gear.

- Axial needle bearing
- Washer with shoulder
- Install with smooth side facing axial needle bearing
- Large sun gear

Fig 8: Installing Washer With Axial Needle Bearing In Large Sun Gear

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Install large sun gear with bearing.
- Center both washers with axial needle bearing between sun gears.

Fig 9: Installing Large Sun Gear

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Install axial needle bearing and needle bearing in large drive shaft.

Fig 10: Installing Axial Needle Bearing

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Install large drive shaft with bearing.

Fig 11: Installing Large Drive Shaft With Bearing

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Install small drive shaft.

Fig 12: Installing Small Drive Shaft

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Install small drive shaft bolt -1- with washer -2- and shim -3-.
- Tightening torque: 30 Nm (22 ft lb)

Fig 13: Installing Small Drive Shaft Bolt With Washer & Shim

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NOTE:

Install shim -3- onto small drive shaft shoulder (arrow).
Determining shim thickness. See PLANET CARRIER, ADJUSTING .

Carry out planet carrier check measurement.

See PLANET CARRIER CHECK MEASUREMENT .

Install axial needle bearing with washers in 4th gear clutch -K3-.

- Axial needle bearing washer
- Axial needle bearing
- Axial needle bearing washer
- Install with smooth side facing -K3-.
- 3rd and 4th gear clutch -K3-

Fig 14: Installing Axial Needle Bearing Components

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NOTE: Make sure that piston rings seat correctly.

Install axial needle bearing with washer on 4th gear clutch -K3-.

- Axial needle bearing with washer
- Moisten axial needle bearing washer with ATF so that bearing -1-, while installing, sticks to -K3-.
- Install bearing washer on -K3-.
- 3rd and 4th gear clutch -K3-

Fig 15: Installing Axial Needle Bearing With Washer

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Install 3rd and 4th gear clutch -K3-.
- Transmissions from 01.93: -K3- clutch operates only 4th gear. See TRANSMISSIONS FOR VEHICLES WITH ELECTRONIC PROGRAM SWITCH IN TRANSMISSION CONTROL MODULE (TCM) .

Fig 16: Installing 3rd And 4th Gear Clutch

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Install shims -a- in -K1-.

Fig 17: Installing Shims

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NOTE:

Re-measure shim when replacing -K1-, -K2- or ATF pump. See CLUTCH PLAY BETWEEN -K1- AND -K2-, ADJUSTING .
1 or 2 shims can be installed.

Install 1st to 3rd gear clutch -K1-.

Fig 18: Installing 1st To 3rd Gear Clutch

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Install reverse gear clutch -K2-.
Install supporting tube for plate set -B2- (arrow) so that supporting tube groove engages in free wheel wedge.

Fig 19: Installing Supporting Tube For Plate Set

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Install -B2- plates as follows:
First install a 3 mm (0.118 in.) thick outer plate.
Install three spring caps in outer plate.
Install compression springs (arrows).

Fig 20: Installing Compression Springs

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Install all but the last outer plate.
Before installing the last outer plate, install three spring caps onto compression springs.

Fig 21: Installing Spring Caps

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NOTE: When replacing:

Supporting tube
the ATF pump
or the plates

The 2nd and 4th gear brakes -B2- are to be adjusted. See 2ND AND 4TH GEAR BRAKE - B2-, ADJUSTING .

Replace corrugated washer.
Replace ATF pump seal.
Install O-ring on ATF pump.
Install ATF pump.

Fig 22: Installing ATF Pump

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Tighten bolts evenly, alternating cross-wise.
- Tightening torque: 8 Nm (71 in lb) plus an additional 1/4-turn (90 °)
- Additional 1/4-turn can be done in several stages.

NOTE:

Make sure that the O-ring is not damaged.

Carry out check measurement of clutch play. See CHECK MEASUREMENT (CLUTCH PLAY) .
Install sealing plugs, valve body and oil pan. See VALVE BODY, REMOVING AND INSTALLING .
Install cover with gasket and spacer bushings.