Assembling planetary gearbox

• Fit O-ring into planet carrier.

• Insert axial needle bearing with washers and planet carrier in input gear as follows:

1 - Input gear is installed in transmission housing. Refer to Planetary gearbox, disassembling and assembling -Overview- 

2 - Axial needle bearing washer, insert smooth side into input gear

3 - Axial needle bearing

4 - Axial needle bearing washer

5 - Install planet carrier with seal installed

• Place washer and axial needle bearing on small sun gear in planet carrier.
• Centralize washer and axial needle bearing in small sun gear.
• Insert inner and outer -B1- plates.
• Insert pressure plate with flat side facing plates.

The thickness of the pressure plate varies according to the number of plates. The replacement part is determined according to the transmission code letters.

• Insert dished washer with convex facing freewheel.

• Preload freewheel rollers with assembly ring 3267 and insert free wheel.

• Install circlip for freewheel -b- and circlip for supporting tube -a-.
• Insert circlip gaps over freewheel retaining wedge (arrow).
• Install Transmission vehicle speed sender -G38-.

Refer to 01 ON BOARD DIAGNOSTIC (OBD) ; Electrical/electronic components / locations

• Perform measurement check of -B1-. Refer to Reverse gear brake -B1- check measurement  .

• Insert components into transmission housing starting with large sun wheel down to small input shaft.

1 - Large sun wheel

2 - Needle bearing washer

(collar faces large sun wheel)

3 - Axial needle bearing

4 - Large input shaft

5 - Axial needle bearing

6 - Needle bearing

7 - Small input shaft

• Install small drive shaft bolt -1- with washer -2- and shim -3-, Tightening torque 30 Nm.
• Insert shim -3- onto small input shaft shoulder (arrow).

• Perform planet carrier check measurement. Refer to Planet carrier check measurement  .

• Clip axial needle bearing with thrust washer to 3rd and 4th gear clutch -K3-.

1 - Axial needle bearing with thrust washer

2 - 3rd and 4th gear clutch -K3-

• Ensure piston rings seat correctly on -K3-.
• Ensure that ends of piston rings are hooked together.

• Insert 1st to 3rd gear clutches -K1- with 3rd and 4th gear clutch -K3-.

• Insert shims (arrow) in -K1-.

• Insert reverse gear clutch -K2-.
• Insert supporting tube for -B2- plate set (arrow) so that supporting tube groove engages in freewheel wedge.

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

• Insert all, but last outer plate
• Insert three spring caps onto compression springs.
• Insert last outer plate, 3 mm thick.
• Determine shim. Refer to 2nd and 4th gear brake -B2-, adjusting  .

• Install shim -a-.
• Insert retaining ring -b- onto shim. Smooth side facing shim.

• Clean strainer.

• Install strainer.

• Install ATF pump seal.

• Fit O-ring on ATF pump.

• Install ATF pump.
• Tighten bolts evenly, in a crosswise pattern.

• Then turn bolts 90 ° further.

Turning further can be done in several stages.

• Perform check measurement of clutch play. Refer to Check measurement (clutch play)  .

• Insert sealing plugs with O-rings (arrow).

Installed position: Tab engages in oil channel.

• Install valve body with conductor strip. Refer to Valve body, removing and installing  .
• Install oil pan. Refer to Valve body, removing and installing  .

• Install cover (arrow) with gasket and spacer bushes.

Tightening torque: 8 Nm.

• Screw in ATF overflow pipe -1- and sealing plug -2- with new seal hand tight.
• Install torque converter.
• Install transmission. Refer to Transmission, removing and installing  .
• Fill with 3 liters of ATF. Refer to ATF, replacing  and check ATF level and top-up. Refer to ATF level, checking and topping up  .