Transmission, Assembling: Notes

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Special tools, testers and auxiliary items required

Spacer pins T10317
Straightedge T40100

Install freewheel.

Fig 1: Identifying The Freewheel Fits In Only One Position

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Use smallest lug for orientation. The freewheel fits in only one position.

All the following parts also have a similar small lug. The lugs must always be aligned.

For better orientation, the parts will be shown in cutaway figures in subsequent steps.

Fig 2: Identifying Correct Installation Of Freewheel

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The installed freewheel looks like this in cutaway transmission:

The freewheel is secured with a retaining ring.

Fig 3: Identifying Installed Retaining Ring

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Install retaining ring.

The open side of ring faces selector shaft. The - ends - of ring absolutely must be installed as shown in this figure.

Fig 4: Insert First Outer Plate Of Brake "B1" With Smooth Side Upwards

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Insert first outer plate of brake "B1" with smooth side upwards.

The underside has a shoulder. This is for freewheel retaining ring.

Use smallest lug for orientation. The outer plates installs in one position only.

Insert first inner plate of "B1".
Install all remaining plates alternately.

Insert last outer plate, approximately 2.5 mm thick.

Align teeth of inner plates.

This will ease the later installation of clutch "K1".

Fig 5: Identifying Dished Spring

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Insert dished spring - A - with convex side upwards.

Fig 6: Identifying Dished Spring Outer Edge On Last Outer Plate

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The outer edge of dished spring - A - lies on last outer plate.

Fig 7: Insert Spring Seat

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Insert spring seat.

Fig 8: Insert Spring

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Insert spring.
Now examine "B1" piston. There are a lug and a hole on outer circumference.

NOTE:

The "B1 piston" must not be inserted while "valve body" installed.

Fig 9: Insert "B1" Piston As Shown

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Insert "B1" piston as shown in the figure.

Carefully guide spindle of assembly tool 3253/3 through spur gear because sleeve on lower end must not be damaged.

Fig 10: Using Assembly Tool T10064/1 , T10064/6A And Spindle From Assembly Tool 3253/3

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Press down piston to stop using assembly tool T10064/1 , T10064/6A and spindle from assembly tool 3253/3.
Install retaining ring.

Fig 11: Ring Must Absolutely Be Installed As Shown In This Figure

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No tool is shown here so that it can be seen how to install the retaining ring.

The open side of ring faces opening to band brake. Here, the - ends - of the ring must absolutely be installed as shown in this figure.

Fig 12: The Hole In Piston Must Be Visible In Valve Body

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Check position of piston!

The - hole - arrow - in piston must be visible in valve body.

Remove assembly tool.

Fig 13: Attaching Needle Bearing To Clutch "K1" With Petroleum Jelly

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Attach needle bearing to clutch "K1" with petroleum jelly (e.g. Vaseline).

The dark side faces transmission.

Carefully insert clutch "K1".

Fig 14: Turning Clutch To Left

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Turn clutch to left. This will cause it to slide into the freewheel.

Fig 15: Identifying Edges Of Bearing Seat & Clutch

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The clutch is properly installed if edges - A - of bearing seat and - B - of the clutch are equally high.

Fig 16: Inserting Needle Bearing For Internal Gear

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Insert needle bearing for internal gear.

Fig 17: Attaching Thrust Washer To Internal Gear With Petroleum Jelly

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Attach thrust washer to internal gear with petroleum jelly (e.g. Vaseline).

The washer install in only one position.

Fig 18: Identifying Internal Gear

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Turn internal gear back and forth while inserting it.

Fig 19: Inserting Needle Bearing For Planet Carrier

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Insert needle bearing for planet carrier.

Fig 20: Attaching Thrust Washer To Planet Carrier With Petroleum Jelly

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Attach thrust washer to planet carrier with petroleum jelly (e.g. Vaseline).
Turn planet carrier back and forth while inserting it.

Fig 21: Inserting Needle Thrust Bearing For Large Sun Gear

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Insert needle thrust bearing for large sun gear.

Fig 22: Installing Large Sun Gear

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Install large sun gear.

Fig 23: Attaching Needle Thrust Bearing To Planet Carrier With Petroleum Jelly

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Attach needle thrust bearing to planet carrier with petroleum jelly (e.g. Vaseline).

The dark side faces planet carrier.

Fig 24: Turning Planet Carrier Back And Forth While Inserting It

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Turn planet carrier back and forth while inserting it.

Fig 25: Identifying The Teeth Along The Circumference Are Engaged In The Clutch Cage Of "K1"

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The planet carrier is correctly installed if the teeth along the circumference are engaged in the clutch cage of "K1".

Fig 26: Inserting Needle Thrust Bearing For Internal Gear

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Insert needle thrust bearing for internal gear.

Fig 27: Attaching Thrust Washer In Internal Gear With Petroleum Jelly

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Attach thrust washer in internal gear with petroleum jelly (e.g. Vaseline).

The washer installs in only one position.

Turn internal gear back and forth while installing it.

Fig 28: Attaching Needle Thrust Bearing To Internal Gear With Petroleum Jelly

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Attach needle thrust bearing to internal gear with petroleum jelly (e.g. Vaseline).

Fig 29: Installing Internal Gear

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Install internal gear.

Fig 30: Inserting First Outer Plate Of Brake "B2"

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Insert first outer plate of brake "B2".

It is about 4.2 mm thick.

The outer plates install in only one position.

Fig 31: Inserting First Inner Plate Of "B1"

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Insert first inner plate of "B1".
Install all further plates alternating them. The two outer plates are about 3 mm thick.

There are two versions of the last "B2 outer plate".

I Later transmissions One outer plate about 7.5 mm thick is inserted last.

Fig 32: II Earlier Transmissions Two Outer Plates About 3.8 mm Thick Are Inserted Last

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II Earlier transmissions Two outer plates about 3.8 mm thick are inserted last.

Install retaining ring.

Before continuing assembly, check clearance of "B2".

Checking clearance of 2nd, 4th and 5th gear brake "B2"

Fig 33: Measuring Value At Last Outer Plate Of "B2"

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Measure and note value at last outer plate of "B2".

Example: 26.15 mm

Press piston of "B2" into cover to stop.

Fig 34: Measuring From Across Two Lugs Of "B2 Piston" To Sealing Surface Of Cover

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Measure from across two lugs of "B2 piston" to sealing surface of cover and note value.

Example: 25.37 mm

Subtract lesser of two measurements from greater.

Example: 26.15 mm - 25.37 mm = 0.78 mm

Specification: 0.60 - 0.90 mm

Fig 35: Attaching Needle Thrust Bearing In "K2/K3" With Petroleum Jelly

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Attach needle thrust bearing in "K2/K3" with petroleum jelly (e.g. Vaseline).
Turn "K2/K3" back and forth when installing it.

Fig 36: Inserting Needle Thrust Bearing

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Insert needle thrust bearing - A -.
Lay thrust washer on bearing (it is stuck in cover).

Before continuing assembly, first check axial play of entire planetary gear set.