Assembling planetary gearbox

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Fig 1: Fitting O-Ring Into Planet Carrier

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Fit O-ring into planet carrier.

NOTE: After replacing planet carrier, adjust. Refer to Planet carrier, adjustments .

Fig 2: Inserting Axial Needle Bearing With Washers And Planet Carrier In Input Gear

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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

Fig 3: Placing Washer And Axial Needle Bearing On Small Sun Gear In Planet Carrier

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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.

Fig 4: Identifying Planet Carrier With Dished Spring

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Insert dished washer with convex facing freewheel.

NOTE: When replacing

Transmission housing
Freewheel
Piston for reverse gear brake -B1-
or plates

then adjust -B1-. Refer to Reverse gear brake -B1-, adjusting .

Fig 5: Identifying Assembly Ring 3267

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

Fig 6: Identifying Supporting Tube Circlip, Freewheel Circlip & Freewheel Retaining Wedge

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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 .

Fig 7: Exploded View Of Transmission Housing Components

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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

Fig 8: Identifying Small Drive Shaft Bolt, Washer, Shim & Small Input Shaft Shoulder

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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).

NOTE: Determining shim thickness. Refer to adjusting planet carrier, Planet carrier, adjustments .

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

Fig 9: Identifying Axial Needle Bearing With Thrust Washer & 3rd And 4th Gear Clutch -K3-

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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-

Fig 10: Identifying Piston Rings On -K3-

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

Fig 11: Identifying 1st To 3rd Gear Clutches -K1- With 3rd And 4th Gear Clutch -K3-

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

Fig 12: Identifying Shims In -K1-

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Insert shims (arrow) in -K1-.

NOTE:

Remeasure shim when replacing -K1-, -K2- or ATF pump. Refer to adjusting clutch play between -K1- and -K2-, Clutch play between -K1- and -K2-, adjusting .
1 or 2 shims can be installed.

Fig 13: Identifying Reverse Gear Clutch -K2-

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

Fig 14: Identifying Compression Springs

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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 .

Fig 15: Identifying Shim & Retaining Ring

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

NOTE: When replacing

Transmission housing
Supporting tube
ATF pump
Retaining ring
or the plates

then the 2nd and 4th gear brakes -B2- are to be adjusted. Refer to 2nd and 4th gear brake -B2-, adjusting .

These components are determined as replacement parts according to the transmission code letters.

Clean strainer.

Fig 16: Identifying Strainer

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Install strainer.

NOTE: The strainer is located in the ATF cooler pipe.

Install ATF pump seal.

Fit O-ring on ATF pump.

Fig 17: Identifying ATF Pump

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

NOTE:

Ensure that the O-ring is not damaged.
Tightening torque: 8 Nm.

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) .

Fig 18: Identifying Sealing Plugs With O-Rings

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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 .

Fig 19: Identifying Transmission Housing Cover With Gasket

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Install cover (arrow) with gasket and spacer bushes.

Tightening torque: 8 Nm.

Fig 20: Identifying ATF Overflow Pipe And Sealing Plug

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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 .