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Transmission Reassembly

NOTE: Soak all new bands and disc brake plates in ATF for approximately 1 hour prior to installation.
  1. Place transmission case in a holding fixture. Install "O" ring and radial sealing ring into selector lever shaft bores. Install closing plug with a new aluminum sealing ring. Install "O" rings and Teflon seals on clutch K-2 support flange and bore in transmission case. Install band B-2 thrust body and plate in upward direction. Install support flange and attaching bolts.
  2. Install thrust washer so plate for torsion lock is fixed in housing. Compress band B-2 on supporting lugs as much as possible and install in transmission case. Place clutch K-2 on planetary gear set assembly. While rotating input shaft, install planetary gear set assembly into transmission case.
  3. Place transmission in a vertical position so input shaft points upward. Check that planetary gear set assembly is properly installed. Planetary gear set is properly installed when upper edge of connecting carrier is lower than supporting surface of disc outside plate. Mount front cover on primary pump.
    DISC BRAKE CLUTCH PLATE USAGE CHART

    Application Steel Plates Composition Plates
    All Models 4 4
  4. Install disc brake clutch plates. See Disc Brake Clutch Plate Usage Chart.  Place a parallel bar on machined surface of transmission case. Place top of depth gauge on bar and tip of depth gauge on compensating washer. See Fig. 19.  Measure and record distance.
  5. Place a parallel bar on top of disc brake piston. Place top of depth gauge on parallel bar and tip of depth gauge on piston gasket. See Fig. 20.  Measure and record distance. Difference between this measurement and the one taken in step 4  ) is disc brake release clearance. Clearance should be .059-.079" (1.5-2.0 mm). Clearance can be adjusted with compensating washers and steel plates of various thicknesses.
    Fig 1: Measuring Disc Brake Release Clearance
    G93C25009Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  6. Place axial bearing into planetary gear carrier. Place groove in input shaft with grease and install grease pressure ring. Connect assembly lock to band B-1. Rotate clutch K-1 to provide meshing of teeth. Install band B-1 so pin of assembly lock is facing toward band B-1 thrust body. Install axial bearing.
  7. Place gasket on front cover. Place a parallel bar on clutch K-1 flange. Place top of depth gauge on bar and tip of depth gauge on gasket of front cover. See Fig. 21.  Measure and record distance.
  8. Place parallel bar on machined surface of transmission case. Place top of depth gauge on bar and tip of depth gauge on roller of axial bearing. See Fig. 22.  Measure and record distance. Difference between this measurement and measurement taken in step 7  ) is clutch K-1 end clearance. Clearance should be .031" (.8 mm). Clearance can be adjusted with compensating washers under washer for axial bearing.
    Fig 2: Measuring Disc Brake Release Clearance
    G93G25011Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 3: Measuring Clutch K-1 End Clearance
    G00308759Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  9. Position front cover on transmission case. Install front cover-to-transmission case attaching bolts. Position transmission case so output shaft is pointing upward. Place circlip into its groove on output shaft. Install helical gear on output shaft. Install governor axial holder.
  10. Install "O" ring in governor bore and install governor. Swivel axial holder toward governor so it will enter groove in governor shaft. Install governor and retaining ring. Pull cover out so it rests on retaining ring all the way around.
  11. Install intermediate plate and "O" ring. Install secondary pump and pump attaching bolts. Check that governor axial holder is properly seated. Install governor axial holder nut. Install oil pipe and attaching bolt. Install detent plate and shaft. Install detent plate-to-case attaching bolt.
    Fig 4: Measuring Clutch K-1 End Clearance
    G00308763Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  12. Mount resilient linkage on detent plate. Mount roller on resilient linkage. Install plastic guide over roller. Place compensating washers on helical gear. Mount parking lock pawl, insert expanding spring and attach spring to parking lock pawl. Install parking lock wheel.
  13. Install measuring sleeve (126 589 04 16 00) over output shaft and tighten slot nut. Engage parking lock pawl to hold assembly from turning. Place a parallel bar across rear cover mounting surface on transmission case. Measure distance from top on parallel bar to lip of measuring sleeve. See Measuring Output Shaft End Play .  Add .59" (15 mm) to measurement to compensate for height of parallel bar and lip in measuring sleeve.
    Fig 5: Measuring Output Shaft End Play
    G00308767Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  14. Assemble rear cover. using a depth gauge, measure distance from rear cover sealing surface to inner race of radial bearing. Subtract this measurement from measurement made in step 13  ) to obtain output shaft end play. End play should be .011-.019" (.3-.5 mm). End play can be adjusted by adding or removing compensating washers under parking lock wheel.
  15. Install rear cover assembly and rear cover-to-transmission case attaching bolts. Install washer for 3-arm flange on output shaft. Insert "O" ring into 3-arm flange. Slide 3-arm flange onto output shaft and install slot nut. Install kickdown solenoid valve. Stake 3-arm flange slot nut into groove in output shaft.
  16. Install thrust pin in band B-1 thrust body. Install thrust body in transmission case. Install modulating pressure control valve. Install vacuum control unit and retaining plate. Install starter lock-out switch. Install range selector lever. Install range selector lever retaining bolt and nut. Install cotter pin in range selector lever.
  17. Install band B-1 guide into transmission case. Install lip seal on band B-1 piston. Using a compressor tool, install band B-1 compression spring and piston. Install locking ring and remove compressor tool. Insert thrust pin for band B-2 into transmission case. Make sure large end of pin is toward band.
  18. Install Teflon ring onto band B-2 piston. Install thrust pin in piston. Place band B-2 piston into transmission case bore making sure that thrust pin enters band B-2. Install band B-2 piston cover and locking ring. Measure release clearance of band from inside transmission case. Band B-2 release clearance should be .24-.28" (6-7 mm). Adjust clearance by exchanging thrust pins.
  19. Install one-way valve and guide for band B-2. Connect control pressure cable-to-connecting rod. Push plastic sleeve of control pressure cable into transmission case bore. Install lower cover making sure that oil pipe enters bore in transmission case.
  20. Place intermediate plate on transmission case. Install plate attaching bolts. Install leaf spring with holder and attaching bolt. Install valve body making sure that range selector valve engages drive detent plate. Install valve body-to-transmission case attaching bolts. Install oil filter and attaching bolts. Install oil pan with new gasket.
    TIGHTENING SPECIFICATIONS

    Application Ft. Lbs. (N.m)
    Converter Drain Plug 10 (14)
    Converter-to-Drive Plate 31 (42)
    Front Cover-to-Case 20 (27)
    Front Cover-to-Primary Pump 15 (21)
    Kickdown Solenoid Valve 14 (20)
    Oil Drain Plug 10 (14)
    Propeller Shaft Clamping Nut 22 (30)
    Rear Cover-to-Case 14 (20)
    Transmission-to-Engine
    M10 Bolts 41 (55)
    M12 Bolts 48 (65)
    3-Arm Flange Slot 89 (120)
    INCH Lbs. (N.m) 
    Clutch K-2 Support Flange-to-Case 96 (11)
    Governer Axial Holder Nut 72 (8)
    Lower Cover-to-Case 72 (8)
    Oil Filter-to-Valve Body 36 (4)
    Oil Pan-to-Case 72 (8)
    Range Selector Lever Nut 72 (8)
    Secondary Pump-to-Case 72 (8)
    Vacuum Control Unit-to-Case 72 (8)
    Valve Body-to-Case 72 (8)
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