08 Auto Gearbox

8/3/2019 08 Auto Gearbox

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AUTOMATIC GEARBOX 2.5CONTENTS

Description and Operation PageAutomatic gearbox components 3General 5Torque converter 5Gearbox 7Hydraulic system 8Differential 14

Adjustments PageAutomatic gearbox - drain and refill 1Hydraulic engagement - check console fitted 2Selector cable - adjust 3Hydraulic engagement - check console removed 4Kickdown cable - check/adjust 5

Repairs PageKickdown cable - renew 1Starter inhibitor/reverse light switch - renew 2Selector cable - renew 3Gearbox and torque converter - renew .4End cover - renew 7Gearbox casing - renew 8Mainshaft - renew 12Countershaft - renew 14Lock- up control solenoid/terminal block - renew 17Clutch - renew 18Governor - renew 20Lock - up valve body assembly - renew 21Regulator valve body assembly - renew 22Reverse selector fork - renew 23Servo valve body assembly - renew 24Secondary valve body assembly - renew 26Main valve body assembly - renew 28Differential assembly - renew 30Torque converter housing - renew 36Selector slide indicator - renew 38

NOTESSymbols have the following meanings:;. ;:;WARNINGii. = CAUTION;. = NOTE= TORQUE WRENCH FIGURE

E ! = SERVICE TOOLm = FASTCHECK TOOL~ = NON REUSABLE ITEMri = INFORMATION


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AUTOMATIC GEARBOX 2.5D ESCR IPTIO N A ND O PER ATlO N

2 Description and Operation


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AUTOMATIC GEARBOX 2.51. Torque converter 49. Governor assembly2. 0 ring 50. Main valve body3. Differential oil separator plate bearingseal 51. Main valve body ..99. Reverse idler gear. ,4. Locating dowel 52. Converter check 100. Gasket5. Oil seal valve and spring 101. Gearbox casing

S. Bearing.~.s3. :9il pump gears . 102. Reverse idler shaft7. Selector shaft oil 1, '1)4. . Oil pump shaft 103. Retainerseal -. 55. Stator shaft'~ 104. Throttle lever8. Converter housing ' :S6.0 ring' assembly9. Oil feed hose .57~Regulator valve 105. Throttle shaft10. Banjo bolt assfmbly 106. Parking pawl11. Sealing washers 58:Cii~lip . assembly12. Throttle lever 59. :,Ne.edlebearing 107. Breather cap

assembly S O . Sealing rings . 10a. Breather13. Oil pipe 61. Separator plate':>, ?" 09. Lifting eye14. Banjo bolt 6 2 . Lock up valve, 110. Cable retainer15. Sealing washers assembly , 'i'l'~ 1. Tabwasher16. Oil baffle plate .~. Mounting plate .c ' ; ". ~.: . '11-2. Shouldered collar17. Countershaft bearing 64. Connector blockf'\j13. Thrust washer18. Counters haft ,*" ,6S;',Connector leads ~n4.Mainshaft 1st gear19. Differential pinion .,. 86. Dipstick and tube 115. Needle bearing

assembly ..' ':t,:"


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AUTOMATIC GEARBOX 2.5DESCRIPTION AND OPERATION

CUTAWAY OF GEARBOX1. Torque converter2. Valve bodies3. Mainshaft 2nd gear4. 2nd clutch5. 4th clutchS.Gearbox breather7. 4th gear8. Mainshaft reverse gear9. Mainshaft 1st gear10. 1st clutch11. Parking gear

12. Countershaft 1st gear and one wayclutch assembly

13. Countershaft reverse gear14. Countershaft 4th gear15. Countershaft16..Countershaft 2nd gear17. Countershaft 3rd gear18. 3rd clutch19. Differential assembly20. Governor assembly21. Mainshaft

4. Description and Operation


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AUTOMATIC GEARBOX 2.5

GENERAL

The assembly comprises a torque converter coupled to a dual shaft gearbox, The gearbox has four forwardspeeds and one reverse: gear changes will occur automatically depe.nding upon selector position, vehicle roadspeed and throttle position. The selector has six positions:- Par~ 'P', 'Reverse 'R', Neutral 'N', '04', '03and '2'. The torque converter and drive plate assembly is splined directly on to the end of the enginecrankshaft and the gearbox mainshaft and incorporates a 10ck-.CI.p,t.IlIe.qhanismwhich is operated hydraulicallywith the timing of the loc~-up ~oPtil1:!,~~,~dt:$yelectronic ecntret. The n'iainshaft and countershaft run parallelto each other and carry the" clutcp..8s,;gears and parking gea,r.The '04' position gives 1-2-3-4upshift$and 4-3-2-1 down$hiftSL tlfe '03' position gives 1-2-3 upshifts and3-2-1 downshifts. The remaining posit.rids '2'. In this gear s~lection, the car will move off from rest insecond gear and remain in this gear with'n~ upshifts or downs:' . Second gear gives maximum engine brakingand can be used for driving on slippery or loose road surfac~' "", ;"

9 .." ... "

All gears run on needle roller bearings except 2nd gear on the'ountershaft which is splined directly to theshaft. All gears, except reverse on the,mainshaft are in constant. mesh with their corresponding gear on thecountershaft. Reverse gear is setected rnanuallv via a selecto .,fork. Orive is transmitted from the mainshaftto the countershaft by the engagement' of clutches or reverse idler gear.

TOROUE CONVERTERThe torque converter is of 'the three efement type comprising an impeller, stator and turbine andincorporating an electroni~~t,;controlled'l.oek-uP mechanism which locks the turbine to the impeller in '0'range, depending on vehicl1r1sp', ~~'throttle pOSition. The stator is splined to the stator shaft whichapplies an additional forceo,h"'.:iil'41atprvalvejclu'ting acceleration. Thi$ increases line pressure andprovides an additional claif,ping p a~'onthe 'clutch plafes. .

I \ _ ~'-.."

The impeller is driven by the engine.'l' ,~ ~,

The stator is situated between the impeller "a'nd: the turbih!l'' 'and incorporates a one-way clutch. The turbinedrives the gearbox via the mainshaft. ., " -, ."'The impeller, stator and turbine are contained within the .torque converter casing. Transmission fluid isunder pressure within the torque converter casing while' the engine is..running. Power is transmitted by theimpeller. As the impeller rotates, the impeller blades pick up fluid"which' is directed by centrifugal forceagainst the blades of the turbine. The fluid striking the turbine blades cabses the turbine to rotate which,in turn, rotates the mainshaft of the gearbox. Fluid leaves the turbine blades and is directed against thestator which redirects it back to the impeller. The blades of the stator are set at an angle to direct thefluid against the impeller is such a way that optimum rotational assistance is given to the impeller.

Description and peranon 5


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1

2 XMOSS9"...~t:l.: :. l'f'2. TurbineTOROUE CONVERTER1. Impeller 3. Stator

The one way (sprag) clutch'preveVt$:Ule stat~r trolt' m~liing' backwards so that accurate redirection of thefluid can be achieved. When the':en,glne'iis Idi~"g,th~impeller blades throw out very little fluid thus theturbine does not rotate. As impell~r ~J:I"ed,.iqcr,a~tis however, the blades throw out more fluid, the turbinebegins to rotate and increases $p,eed,asAhe1eqgine/impeller speed rises. As turbine speed increases, thestator begins to rotate and fluid is ~ir~ted,6a,dk to the impeller. When turbine speed aproaches impellerspeed, centrifugal force in both elements. ,is almost equal and all three elements are moving at almost thesame speed: this is known as the 'coupling point' of the converter.

Torque multiplication or drive ratio varies until a 'one to one' coupling point is reached. To achieve thepower required to climb a'hill the .driver depresses the accelerator pedal and the torque converter reacts byincreasing torque multiplication. When driving on a flat road at cruising speed. the power required is lessand torque multiplication remains at one to one.Lock-up mechanismWith a conventional torque converter, there is always a certain amount of slip between the impeller andturbine. This can contribute to a reduction in fuel economy' especially during high speed cruisingconditions. This is eliminated in this gearbox by a Io,ck-up meehantsm, Lock-up is achieved by a lock-uppiston incorporating a friction lining. When the pistGfI is a,pp!ied"ilv hydraulic pressure, the frictionlining contacts the impeller eliminating sliQ betwe:en the turbjne and impelier. Lock-up is only functionalin 2nd gear and above with '04' select"d. 'depending on coolant temperature. vehicle speed and throttleopening. This system is controlled by governor and throttle pressure and by a lock-up control solenoid valveactivated by the ECU. .EngagedWhen throttle opening. vehicle speed, coolant temperature and governor pressure exceed certain limits. fluidbetween the converter cover and port C piston is discharged, converter pressure enters through the inlet andexerts pressure on the lock-up piston engaging the lining with the impeller. The effect is to by-pass theconverter, thereby placing the torque converter in direct drive.DisengagedWhen throttle opening. vehicle speed, coolant temperature and governor pressure fall below certain limitsconverter pressure enters through port E and moves the lock-up piston away from the impeller disengaging thelining. The lock-up mechanism is now released and the impeller and turbine can rotate at different speeds.Port 0 carries fluid to the cooler.

6 . Description and Operation


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:1'-

LOCK -UP MECHAN/SM .:~A Engaged1. Lock-up piston

B Disengaged2. Damper spring

G E A R B O X~., "i.

1st Clutch " ,< t . ': " '~ : " ': " " 'The 1st clutch is mounted on the mainshaft andk&"i~8VAlydraulic pressure to lock the mainshaft 1stgear to the mainshaft. The mainshaft 1st gear drive~dhe'~i1untershaft 1st gear via a one way clutch.2nd ClutchThe 2nd clutch is mounted on the mainshaft between the 2nd gear and 4th clutch. The clutch is applied byhydraulic pressure and locks the mainshaft 2nd gear to the mainshaft in 2nd gear of '04', 03' and '2'. The1st clutch remains 'ON' in 2nd gear whilst the one way clutch freewheels to prevent the transmission fromlocking up3rd ClutchThe 3rd clutch is mounted on th..cou.n~rsha.'t between the crown wheel and countershaft 3rd gear. The clutchis applied by hydraulic pre5sunt."id)1~ks th.e cot.l!"tershaft 3rd gear to .the countershaft in 3rd gear of '04'and '03'. The 1st clutch,rem~i"s'ON' in 3,d. gear:.aridthe one .way clutch freewheels to prevent thetransmission from locking up! . . ..",4th ClutchThe 4th clutch is mounted on the mainshaft between the 2nd clutch and mainshaft 4th gear. The clutch isapplied by hydraulic pressure and locks the mainshaft 4th gear to the mainshaft in 4th gear. 4th clutch isalso applied when 'R' reverse is selected, mainshaft reverse gear being integral with the mainshaft 4thgear: power is transmitted from the reverse gear to the final drive via the reverse idler gear, countershaftreverse gear and the countershaft. The one way clutch freewheels to prevent the transmission from lockingup.One-way ClutchA sprag type, one-way clutch is fitted between the countershaft 1st gear and parking gear. When both gearsrotate in the same direction, the clutch sprags lock the gears. When the gearbox upshifts from first tosecond, the countershaft turns faster than 1st gear, the parking gear turns in the opposite direction andfreewheels. This also occurs in 2nd and 3rd gears with the gearbox in 3 and also in 2nd: 3rd and 4th gearswith the gearbox in O .Revers. gearWhen 'R' is selected, the reverse selector fork engages with the countershaft reverse gear. Power flows viathe mainshaft reverse gear, reverse idler gear and countershatt reverse gear. Engagement of the selectorfork is assisted by a servo whilst disengagement is spring assisted.


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"AUTOMATIC GEARBOX 2.5DESCRIPTlON AND OPERATION

HYDRAUUC SYSTEMThe hydraulic control block comprises of the oil pump which is driven from the torque converter, and a valvebody. The valve body consists of the main valve body, regulator valve body, sscondarv valve body, servo bodyand lock-up valve body. The lock-up control solenoid valve is attached to the modulator valve located in thetop of the servo body.Hydraulic pressure produced by the oil pump is regulated by the pre~sure regulator valve and directed to theclutches to produce the desired gear ratios.; ,",.HYDRAULIC VALVES f',r';'~:4;';(

"~" . . . ~: -Pressure Regulator Valve ~' y' ' .. ,,'The regu~ator valve controls line pressure to prevent f1uctu~ti~(.:;, c t I)y -yariations in pump speed. Ashaft, sph.ned to the stator at one end, operates a lever whlch';a " 'afor,c. on the regulator valve.During hard acceleration and hill climbing, before convertf)h,ceVa < r i g point is reached, stator pressure isat its greatest, the regulator valve will raise the pressure pro d:tlilf4ncreased clamping load on theclutches preventing slip. .; '~ < , j , : ~ ; :

. ~., , "~~~~ , ~This valve regulates lubricating fluid p(ess!J'r!l;-10the e ::~.ijrshaft. When the pressure increases, thespring is compressed and the valve' opense\c~.au~'in~~~Etxciesspressure.

1;'~'A:.: : :~:~


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P3

/1.;'i, ' < ~ I ' 1 ' c

~1l...."I:I" '--t:~:::;: .~:(' .:(,;; '" ."1-2, 2-3 AND 3-4SHIFlrVALVES1, 1-2 Shift v.lve "" ' . ; " " ; ' l > : 'k2. 2-3 Shift valve'3. 3-4 Shift valve'4. 3-2 Timing valve

XM06745. Clutch pressure controlP1 Governor PressureP2 Throttle Pressure 'A'

, < I ' , . . . . _ ' , ' . 1 ' 3 - Throttle Pressure'S'; ; _ .; . c : ,"':".~4 ',~,Clutch Pressure Control )lalve 'f " " " :1This valve controls line pressure dependant upon' throtll pr'~$ure :A', Clutch pressure to the 1-2 shiftvalve is reduced during low throttle pressure conditions alleviating shocks in gear shifting.~ .3-2 Timing ValveThe 3-2 timing valve prevents a 3:-2 shift occuring when there is only a small increase in throttle pressure'A.'. When throttle pressure reaches a certain level, the 3-2 timing valve moves allowing throttle pressure'A' to the 2-3 shift valve.Shift Timing Valve and Timing Accumulator .PistonIn '2', second clutch pressure moves the shift timing valve (4) thus overcoming spring pressure. This closesthe governor pressure passage (2) to the.t3-::-4shift valve (3) preventing a 2-4 shift, At the same time, thetiming accumulator (1) is charged .with fluid (2ndohst'cl'l pressure Pl). This maintains pressure in the shifttiming valve circuit for a $hort time durin~'a. 2:t3shift t.husensuring that 3rd clutch pressure is raisedsufficiently to engage 3rdgear before the 3-4': shift V"alve(3) moves. This eliminates shock during 3-4shifts. 1 - ,

2

XM0678SHIFT TIMING VALVEAND TIMING ACCUMULATOR PISTONt. Timing eecumulator piston2. Governor pressure3. 3-4 Shift v.lve

4. Shift timing valvePl 2nd Clutch Pressure

and Operation 9


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~~;~(,,~..Kickdown ValveThis valve controls the exhaust pr.es~.,!~ref ti:1e4th c.irctt~,I.',: During 4-3 kickdown, the remaining pressure in the 4th accumulator is applied unt'ilthe. 3 ' M t . or 2nd cluteh>


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AUTOMATIC GEARBOX 2.5Throttle Valve '8'This valve receives line pressure (P4t and converts it into throttle pressure '8' (P3t. Throttle pressure'S' (P3) will vary depending upon throttle opening and wiU"act upon the accumulators .

4XMOS7S

THROTTLE VAL VE '8'Pl Throttle Pressure AP2 Modulator PressureP3 Throttle Pressure BP4 Line Pressure

1. Throttle valve A2. Modulator valve3. Throttle valve B4. Filter

Modulator ValveThis valve modulates line pressure which is directed and used by throttle valve 'A' and the lock-up controlsolenoid valve.Throttle Valve 'A'This valve receives modulator pressure and converts it into throttle pressure 'A'. This pressure will varydependant on throttle opening and is used on the shift valves to provide automatic gear changes.ANote The adjustment of throttle valve 'A' is pre-set during manufacture and must not be altered.1st AccumulatorThis is connected in the 1st clutch hydraulic circuit and comprises a piston and spring. When 15t clutch isapplied, the piston in the accumulator moves damping the 1st clutch application.2nd, 3rd and 4th AccumulatorsThese operate in a similar manner to the 1st accumulator except that throttle pressure'S' (Pl) acts on thespring side of the piston. The damping effect of the accumulator changes depending upon throttle opening .

Description and eration 11


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Servo ValveThis operates the reverse selector fork whic'h!i"loves a.'couplingsleev, engaging the teeth on reverse hub withthe teeth on the reverse countershaft gear. . . ..'. .ANote Servo body and servo valves are mat~Aed sets and come 'in three sizes A . 8 and C. It a servo valve is changed. one must be fitted with the same letters. .r,

AUTOMATIC GEARBOX 2.5DeSCRIPTION AND OPERAnON

1 2

..1.:, . ;to

2nd, 3rd AND 4th A c c u M i l i i lJ l J l.' " .~~~ : ,.. ,~~". ; ; :" } ~ ~ ~ t , , 3. Clutch pressureP1 Throttl8i.,pressure B1. Accumulator piston2. Accumulator springGovernorThe governor is driven by a' gear which meshes with the final drive gear.-Wlthin the governor body is agovernor valve which incorporates primary and secondary spring load9d,vJ~igtits. Operation Line pressureenters the governor via a passage around the outside of the drive spinelle."When the vehicle is stationary,the governor valve is at rest and no governor pressure enters the governor lines. As vehicle speedincreases. the governor weights move outwards and allow more line pressure to pass through the valve via apipe, inside the drive spindle into the governor lines. Governor pressul'e is then proportional to vehiclespeed. . '

4

S E R VO V A LV E1. Se~o valve2. 4th ~Iutch feed3. Reverse control valve

4. Servo valve feedP1 Governor pressureP2 Line pressure



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AUTOMATIC GEARBOX 2.5II .

, . . . P52 r-I~~

~l I. L [ : : ; ; - I \.J: , - - . . . . . .C l Ir ........~ (r o 1IT

-

TORQUE CONVERTER LOCK-UP CONTROL VALVES XM07021. Lock-up solenoid2. Lock-up cut valve3. Lock-up timing valve A4. Check valve5. Lock-up timing valve B6. Lock-up shift valve

7. Lock-up control valveP1 Modulator pressureP2 Throttle pressure AP3 Governor pressureP4 Converter pressureP5 Line pressure

'on and Operation


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AurOM ATIC GEARBOX 2.5, DESCRIPTION AND OPERATION

Reverse Control ValveThis valve controls the engagement of reverse gear depending on line pressure and governor pressure.Torque Converter Lock-up Control ValvasThese consist of several valves which control timing of the lock-up piston preventing the lock-up pistonfrom vibrating in the lock-up condition.Lock-up Cut ValveThe lock-up cut valve (2) switches the line pressure port to the lock-up:timing valve 'A' (3). Whenmodulator pressure (P1) is applied to the lock-up cut valve, the ,por.t;.t~ the lock-up clutch is closed. Whenthe lock-up control solenoid (1) isener'gised, modulator pressure:exhausts and line pressure to the lock-upcut valve is transmitted to the 'lock-up timing valve A (3). __ ~.-. . ~ ,~Note The lock-up control solenoid is activated by the P G M - 1 = I : e c i J d,ependant upon signals from the vehiclespeed sensor, ooolant sen,sor and throttle angle sensor.Lock-up Timing Valve 'A' , ,_The lock-up timing valve 'A' (3) switches line pressure (PS) frbin;tl:lj,'lock-up cut valve (2 ) to the lock-upshift valve (6). When governor pressure ' (P3) overcomes sprh'lg'f",r:essure, the valve opens allowing linepressure to the lock-up shift valv'{.F ,,!>,, ' ~( >Fourth clutch pressure is applied to'tfle, timing valve whie ':asststs the spring tension during fourth speed

.. L \,.+'.' ...range, so delaying converter 10ck":uR+, , ': ,. ',,',,' " ' :; ,. :}. . .. .. ,

Lock Sho tt V I ' ,.: ,'" ..~,.o~,,'.-up I ave',:,,': , ":':~',,_,,When lock-up oonditions are fJlJQ14~-~ii.,.t'i_$UI~~~Ve~ the valve. This causes converter pressure to bedirected to the other side of the;,;:ve11,rlocR.,Op.;"p';aton.and lock-up is engaged.. ~...~a 'j.l::" " ' _ i,~ : ', " , , ' . .,,, '- '; ""Lock-up Control Valve ,,_,,', _;:.:[." . ',.'This valva controls the exhaust' pa~~" f r o . m 't1Ie:f~lease side of lock-up piston during lock-up dependingupon throttle pressure'S',Lock-up Timing Valve '8'The final lock-up timing is controlled b'Vthis valve (5) depending upon governor pressure (P3) and throttlepressure 'A' (PS) . When the lock-up shift valve (S ) is in the lock-up position, converter pressure (P4) , isdirected to this valve. When the valve is closed, converter pressure is directed to the lock-up controlvalve (7) and lock-up exhaust oil is controlled. On the other hand, when governor pressure moves the valve,the pressure feed is closed and complete lock-up is achieved.Check Valve"This valve controls converter pressure when lock-up)~,achievecl'. ,r

DIFFERENTIALThe differential is located in the gear9ase:;"d '~hares :tl:l,e..sa~e ,lubricating fluid as the gearbox, Drive tothe differential is from a gear on t'h,~'''eotll..ersbaft., The ring~ear drives the gearbox oil pump whilst a ringgear mounted on the differen,ti'al ear.rier ~ifriyefthe speedometer pinion - see 'Description: The drive shaftsare splined directly into the differenti'al.pinions.



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. .


(

Between MIN and MAX marksA CAUTION Do not overfill

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,Spedal ,Instructions':J

~ "vehicle 2 mile, 3i


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ActionMoveRemove:PositionMarkAlignSecureCheckApplyStartSlowly moveStop whenNoteSlowly moveStop whenNoteStopAdjust

2 Adjustments

AUTOMATIC GEARBOX 2.5ADJUSTMENTS

selector lever - N [neutral]screw - selector handlehandh!t - selector lever1. checking gauge - graphic plate2. selector lever centre line3. gauge centre line - lever mark:gauge -'graphic plat ..,centre line - mark: .'\-' . , . ,i"hand and f09t brakes;engine .. " "

4. selector lever,';'" R'~initial hydraufi,: enga'g'emen~ occursposition of ! ] 1 8 1 t c :S. selectof'.l~ver - 04initial hydraOlic engagement occursposition of markengineselector cable

"::4;0 -;~ .~.: , < , .. . . ;HYDRAUUC ENGAGEMEN7X: ': C.HECK' f ji :iNSoLE FITTED

,,f .~~ '. '_ _ .~ ':,f. c

This procedure can be carried, outt~~teripi"~, whether adjustment to cable is required. It MUSTbe carried out atter adjustrnentjtQto..n.~,(l.sO.:piJ.~t~t,j;'ntting I S accurate and selector quadrant iscorrectly aligned. J~.S~~!!-( ,'. ,.'

,~.: ..~ ,l '~

180 1655

Ref . Detail'.

XM0745

Special Instructions

B 18G1555Use:adhesive tape

~

If initial engagement R or 04 outside lines


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~~~~ : < 5SELECTOR CABLE _ 'M J r J I I S , ..~ActionRemoveSlackenChecltMovePushTightenMoveSlackenTtghtenMoveRe-checkCarry out

Ref. Deta i l Special Instructions1.

centre consolenutcable metal sleeveselector lever - 2metal sleeve forward

See 'Body'Us:e 24 mm, 15/16 in crowsfoot spanner' : wlI i slide through olive

'~~Hold 'f'~ly.' To limit of travel, m 18 Nm, Use 24 mm, 15/16 in crowsfoot spanner2-3.4. nut .c..~ I

selector lever - Nnutnutselectorselector cablehydraulic engagement checkconsole removed

,'.Gear~ox $elector valve centralized in detentm 1B Nnl, Use 24 mm, 15/16 in crowsfoot spannerTo engage all positions on quadrant

justrnents


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Action Ref. Detail Special Instructions'-.J--

Move selector lever - NCentre punch A. selector lever centre lineMarie: 8. quadrant - rearward .~ Ato B 8.5 mm. 0.335 in

C. quadrant - forward A to C 7.5 rnrn, 0.295 inStart engine, Apply foot and parking brakesSlowly move 1 . selector lever - RStop when initial hydraulic engagement occursCheck centre punch - quadrant mark Within 0.5 mrn, 0.020 inSlowly move 2. selector lever - 04Stop when initial hydraulic engagement occursCheck centre punch - quadrant mark Within 0.5 mm. 0.020 in

If not OK. re-adjust cableReassemble componentsRe-check setting gaugeCany out hydraulic engagement check

console fitted

.AUTOMATIC GEARBOX 2.5ADJUSTMENTS

XM051~

HYD RAULIC ENG AG EM ENT'- CHECK CONSOLE REMOVED'This procedure MUST be carried out after selector cable has been adjusted.

4 Adjustments


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XM0 6 6 7'+~ ;'.

KlCKDOWN CABLE - >CH~4 i f .?~f lST..' /j,,~~~,':~.~{r'.: r ~ " . :. .Action Raf. Detail ' , > " , ~ ': 'c

RemoveSlacken

PressScrewTightenCheck:

MoveStartDepressCheckReassemble

2. gearbox lever3. upper locknut - abutment bracket4. lower locknut - abutment bracket5. cable free play

air cleaner1. locknuts - cable

Spacial.InstructionsSee 'Fuel 2.5'2 off'Ii,CAUTION Top locknut must be slackened to. e"d., thread of bracket, D own fully

cable moves freelygearbox lever movement

Gearbox lever must move as soon asthrottle lever is operatedWhen accelerator is fully pressedShould be 2 to 4 mm, 0.08 to 0.16 in furthermovement when accelerator pedal is touchingthe floor

. selector lever -Pengineaccelerator pedalgearbox levercomponents

GraduallyMovement is synchronised with throttle lever

Adjustments


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'~.~ ~.:~. "

' l " .

'.'

~ . ' .


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Action Ref. Detail Slacken 1. locknut - cableRelease 2. cable - bracket and throttle leverSlacken 3 . locknut - cableRelease 4 . nipple - throttle leverWithdraw 5. cableReassemble componentsAdjust cable

AUTOMATIC GEARBOX 2.5REP

KICKDOWN CABLE - RENEWSpecial Instructions

See 'Adjustments'

Repairs


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.AUTOMATIC GEARBOX 2.5' . REPA IRS

S T A R T E R IN H IB IT O R / R E V E R S E LIG H T S W IT C H - F /E N E WAction Detail Special Instructionsef.PositionDisconnectRaiseReleaseRemove:

vehicle on rampearth lead - batteryrampbulb holders - selector housing '.'selector housil'lg" .

1. E clip - cable ,.~2. cable - lever '.'3. nut - cable

nuts - front exhaust pipepipe - manifoldsflange packingsmounting rubbersexhaust assemblypop rivets - lever housing4. bolts - lever housing

5. multiplugs8. lever housing7. detent bracket - housinga bolt - lever9. bolt - switch10. switchcomponents

starter operates in P and N only

2 screws

ReleaseSlacken: 24 mm, 15/16 in crowsfoot spannerS' offReleaseRemoveReleaselower

Drill outRemoveDisconnectRemove:

2 off2 offHeater ductS off2 off

ReassembleCheck

2 Repairs


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Action Ref. DetailRaise: vehicle

bonnetDisconnect earth lead - battery Release bulb holder - selector housingRemove: selector housing1. E clip - selector cable tRelease 2. cable - ' evel 'Slacken 3 . nut -, housingRemove: 4. bolt -cable covers. cable cover - gearbox

longitudinal support - vehicle8 . split pin - selector cable

Withdraw 7 . clevis pinRelease 8. cable - gearbox leverRemove: heat shield

selector cableFit selector cable - converter housingLocate selector cable in leverPosition outer cable retainerReassemble componentsAdjust selector cable


S E LE C TO R C AB LE - R E N E W'S~etnaiInstructions' . . . .. .On ramp'

,.. .

Use 24 mm, '15/16 in crowsfoot spanner

See 'Engine 2.5' for tightening sequence oflongitudinal supportSee 'Adjustments'


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AUTOMATIC GEARBOX 2.5REPAIRS

1 8 " f

GEARBOX AND TORQUE CONVERTER - RENEWAction Ref. Detail Special InstructionsRaiseDisconnectRemovePositionSlackenReleaseRemoveRelease

bonnetearth lead - batterystarter motordrain trayclip - oil cooler hosehose - pipebolt - harness bracketharness

See 'ElectricafUnder gearbox

4 Repairs


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RemoveReleasePlugDrainSlackenRelease:MoveRemoveReleaseRemove:ReleaseRemoveReleaseRemove: Release, SupportMoveRemove:

MoveRemove:


MartRemove:

WithdrawReleaseMoveSupportRemove:MoveRemove:ReteaseRemove:ReleaseRefitRemoveMovePositionTightenFitSupportRelease LowerRelease

1. clips _ oil cooler hose 2 off m 3.3 NmAi CAUTION Ensure hoses are up.}" .3rd rtb, clipbetween 2nd and 3rd rib with s(;rew to outside

2. hoseshose and pipe connectionsfluid _ ge'arbo,x3. locknut - Idekd"own cable4. threiad~ bar - bracketS. nipple - lever6. kiekdow,n cable

nut - top link balrjointball jointsplit pin - ball jointnut _' ball jointtraCK rodnut - bottom swivel jointswivel jointbolt - forkbolt _ forkforkdrive shafts - gearboxsuspension leg ':",drive shaft.(su$pension legtie' ,rQd .. ... 4,_ : .. ._ ,', "scre~~;;: ~r~ P ! ; > 8 ' ,to ABSwirint", ~Cker" ;,~brat'e "tlO'$.e"an ,jbolts ~::-ctt)ss.mbcil;tS''':''snubber 'b~( ,bolt - drive plat.e 'fzsnubber bracket and or/ver ;, ,;;.'"drive plate _ torqUe';:6nve~'~,'/' For reassemblybolts - drive plate:' ' = . ._ ,' , L," 8'offJ~ 12 Nm. Rotate engine to gain accessbolt _ selector cable' cover' ">split pin - clevis pin I ! ! I Secures selector cableclevis pincable - gearboxcable

Fit plug on completion2 off'(~sfde! l f i J c4 a NmI,Js~~:D'1 8G ; 063A"Ii) ,4~_Nm

Use 0 18G 1063AlillOO NmUse~'D 18G 2To' lower arm m 65 NmTo shock absorber m 44 Nm

",

See 'Drive Shafts 2.5'Use hydraulic jackAsideSee 'Suspension'

7 .3 offAside8 off3 'cff

9.10.11.

engine12. bolts - front centre mounting

bolts - rear mounting13. bolt - behind R.H. driveshaft14. bolt - torque rod15. bolts _ tcrque rod bracket, 6. bracket17. bolts18. bolt _ speedometer pinion assembly19. speedometer pinion assembly20. 0 ring _ pinion '

bolt _ earth leadearth lead _ gearbox lifting eyeboltbolt _ harness strapharnesslifting eye

AsideUse trolley jackTo gearbox 2 off m 39 NmTo gearbox 2 off m 39 Nmm 22 NmIi) 40 NmCollect special nut2 off m 40 Nm eAside3 off below throttle bodym 15 NmeIi) 40 Nmm 40 NmAsideUpper eye of torque rod bracket mountingbolt hole

bolt _ lifting eyechainsgearbox on chainsgearboxR.H. drive shaft extensiongearboxchains - gearbox

Manoeuvre gearbox from below vehiele

Continued ....Repairs 5


26/58


< .

XM0 6 6 2

ReleaseRemove: 21.22.23., i > s . ' " . ; 'torque conv..l#itr~: hous;Qgo ring - .torQ~ converterseal - hQUli,ng .

components When fittinlt drive plate to converter,rotate crankshaft to gain access to bolts.Initially t~'half torque then to fulltorque in dtagonal sequenceSe. ~Adjustments'See


27/58

XM069SAE N D C O V E R - R E N E WAction Ref. Detail Special InstructionsRemove: torque converter1. end cover bolts 10 off E D 12 Nm

2- cover3. gasket and 0 rings e4. plugs - end cover 4 off E D 18 Nm5. sealing washers 4 off e

Collect 6- ball and springRemove: 7. circlip - low accumulator

8. accumulator cover9 . springs 2 off10. piston11. o rings 2 off e12- circlips - 1stl3rd clutch accumulator 2 off13. 1st/3rd clutch pipes

Move 14. flanges - down pipes Remove,: 15. pins and washer flanges - pipes16. o rings - flanges 3 off eReassemble: components Lubricate all components with cleantransmission fluid: smear gasket withpetroleum elly

epairs


15(i5

.~~~14 ~/11.-_--12 .

~ , . : . . " , 87


28/58


epairs


29/58

CollectRemove:

EngageRemove:

DisengageRemove:RemovePositionRemove:

Release:Remove:

CollectReleaseRemoveCollectRemove:

WithdrawRemove:

-s -


Ref. Detail Sp~cial Instructionsend eover1. holding tool - mainshaftstaking _ , st elutch nut2. nut _ main""aft3. 15t clutch - mainshaft

4. 1st gear - main5hafts. . bearing$ and thrust washers6.- bearing sleeve - mainshaft7. thrust washer - mainshaft8. 0 rings - mainshaft9. parking pawlstaking - countershaft nut10. nut - countershaft11. parking pawl12. parking gear - countershaft1st gear -'countershaft13. one way clutch - countershaftgearbox14. stop pin1s.. parklng,,!wl18. 5prina .17. shaft18. lock tab _ boffbolt .19. bolt and tabwastter ","20.21.22.23.24.2& .26.27.28.29.30.

stopper - armspringsplit pinroller pin and washerroller and parking brake leverslock tabbolt _ throttle levertabwasherthrottle lever at:'ldspringwash,rbolts _ dipstick tubedipstick tube-,o ring ~.(bolts -tr~s'miP:iif!" 0 ,n9

, . ' ; \" . ' , . '

n 18G 1530&195 Nm fJ"'~ :

& I 95 Nm. nut has a left hand thread.fJ

On eonverter housing facePark lock mechanism

~ , L:. .... II15 Nm fJ tabwasher

6 J 12 Nmem 12 Nme15 off & I 45 NmRemovebolts in order shown

XM0663

Continued ....


30/58

AUTOMATICREPAIRS GEARBOX 2.5

36

10 Repairs


31/58

AUTOMATIC GEARBOX 2.5Remove: 38.

39.WrthdrawCollect 40.Remove: 41.42. 43-44.InspectLubricateCheckReassembleTighten

~:"Vse 8 suitable drift to remove bearings.bolts - holder ..., "... ,.' 2 .off Ii) 12 Nmholder and reverse idl~r sh,1t. - . ; # < ~ \ . ; f . . . , . . .ball and spring '. . ~'>l.$'1'bolt : m 12 Nm

Remove: 31. transmission casing32. gasket

throttle shaft oil seals33. dowels34. reverse idler gear35. bearing

reverse selector fork36. differential bearing outer track37. shims

snap rings - bearingsmainshaft and countershaftbearings - transmission casing

'~bearings and oil seal

ea3 off

CollectRemove:

washerspringshaft

"it:> , : , ' ~ , ~ ,.~,~~~~, .;' I ! ! J

; , . _For wear and damage and renew as necessaryUse transmission fluidIf differential assembly bearings ortransmission easing have been renewed- see 'Differential assembly'Use e laG 1525 when fitting oil sealIn sequence illustrated

XMOS65

Repairs 11


32/58

~. AUTOMATIC GEARBOX 2.5_REPARS

ff'~ 151213/ @14

XM0681

MAINSHAFT - RENEWActionRemove:

CleanLubricateInspectCleanLubricate

12 Repairs

Ref. Special In.Jructions, 'r~ '_."~Detail

1.

end covertransmission casingcountershaftmainshaftsnap ring ,I . . ;4 :t h 9 !, ar bearing . ~ L. ~-' ~ ~..,thrust wa~her, beari'1l,'wfl 4t~:1J.t8rneedle b'8'arings.4th geal' coUAl',thrust 'ne,e~le bearing' and thrlJist )Masher2nd / 4th clutch

2.3.4 .5.6.7.8.9.10.1 1 .12.13.14.15.

2 off erings '. ','2nd gear thrust washer2nd gear thrust bearing2nd gear 'needle bearingthrust needle bearingo ringssnap ringneedle bearingspacer collarmetal sealing ringscomponents

3 off e3 off eUse transmisstcn fluid or chlorinated solventDry components immediatelyUse tran-smi.ssion fluidFor wear, ,renew components as necessaryIn mainsh:e'ftUse transmission fluidANote Thrust needle bearings with open recesswithin the needle cage must be fitted with recessfacing thrust washer

bearingscomponentslubrication holeso rings and metal sealing rings


33/58

r" ~;..

F'rt: 16. metal sealing rings 3 off17. o rings 3 off18. spacer collar19. needle bearing

20. snap ring21. 2nd gear thrust bearing22- needle bearing23. 2nd gear24. o rings 2 off25. 2nd / 4th clutch thrust bearingF'IX 26. 2nd / 4th clutch thrust washer Use petroleum jelly

- clutchLocate 27. 2nd / 4th clutch to mainshaft Engage all clutch platesCheck clutch flange Must be level with top of splinesF'rt: 28. 4th gear thrust washer

29. 4th gear thrust bearing30. 4th gear collar31. needle bearings :2 off32. 4th gear Ensure gear engages with all clutch plates33. thrust bearing34. thrust washer Dished face towards snap ring35. snap rings 2 offLocate 36. mainshaft bearing On mainshaft

F'rt: 37. 1st gear collar Flange of collar towards mainshaft bearing38. , st gear thrust washer39. needle bearing 40. , st gear41. thrust bearing42. thrust washer43. , st clutch Continued ....44. nut


~20~~19 , , ~ 18~ .. 1~~6

,.~~

~~ - '''-J 45


34/58

RemoveFitReassembleFit

AUTOMATIC GEARBOX 2.5mainshattnut

45. clearanceiJ lSG 1530~ 35 NmBetween shoulder of 2nd gear and 3rd gearn Should be 0.07 to 0.15 mmIf clearance is incorrect, proceedOt 2nd/4th clutch thrust washerWhich will give correct clearancen Thrust washers available4.00. .mm, 4.05 mm4.1Ol'hm; 4.15 mm4.2.0 ,mm, 4.25 mm4.3Q.mm, 4.35 mm4.40 mm,Retat". nut for retitting-- ,j~~> . . : ~ : . ~ ~ . :'~~.';;'; mainshaft nut to m 95 Nm'It s . ' N ' r i 'I . nut has a left hand thread;:.~:~~\~' ~ : ~ ~ '

48. thickness

thrust washer

items 36 - 44selected thrust washertransmission casingcomponentsnew countershaft nut

e ,

r-.L

COUNTERSHAFT - RENEwXM0680

ActionRemove:

SlideRemove:

Ref. Special Instructionsetailtransmission casingselector forkmainshaftcountershaft1. 4th gear - countershaft

2. needle bearing3. spacer collar4. 2nd gear5. 2nd gear thrust bearing8. split collar7. 3rd gear8. needle bearing9. 3rd gear thrust bearing10. splined thrust washer11. 3rd clutch12. 0 rings

2 otf segments

2 off e


35/58


Clean componentsLubricate bearingsInspect componentsClean lubrication holesLubricate o ringsFit 13. o rings

14. 3rd clutch15. thrust washer16. thrust bearing17. needle bearing1& 3rd gear Engage clutch plates

25

..J

38,39

32 XM0691Use transmission fluid or chlorinated solventDry components immediatelyUse transmission fluidFor wear, renew as necessaryIn countershaftUse transmission fluid2 off

Fully

Continued ....


36/58

PositionFitTightenMeasure:

Select

RemoveFrtMeasureLeaveSlideMeasureSlideMeasureCompareMeasureSelect

RemoveFitReassembleFit:CompleteReassemble

16 Repairs

AUTOMATIC GEARBOX 2.5REPAJRS19. split collars20. thrust bearing21. 2nd gear22. spacer collar23. 4th gear24. needlebearing25. reverse gear selector

hub and reverse gear26. needle bearing27. collar28. countershaft bearing and snap ring29. collar30. needle bearing31. 1st gear32. one way clutch33. parking gear

countershaft in vice34. new countershaft nut

nut35. clearance

. .36. 4th gear spacer collarcollar

original collarselected collar

37. clearancefeeler gauge3rd gear38. clearance-3rd gear

39. clearancetwo readings

40. splined thrust washerthrust washer

nutthrust washercomponentsmainshafttransmission casingassembly of countershattcomponents

--\, ')~.:; .~t

Groove faces'towards reverse gear~.. : .

U s e , soft jawed vice'l&~Qta)Nut has lett-hand threads' ., ,:~,35)~"m' ,~.$.~~!e'1 ,reverse gear selector hub and':.s1lP\l!Jder~,9n,th gear.

.: rI'shoQJd~be 0.07 to 0.15 mm'S""'. If i! ,:e9rr,pt . proceedLengt ! t :~hicn gi~s correct clearance. .; -. ". t :QUaC engths available'47~SO~, 47.55 mm47.601"11'"":4.7.65mm47.70mm.47.75 mm47:aOmm ,,' .'"

\ .

Between reverse selector hub and 4th gearIn positionTowards 2nd gearB.!Stween 2nd and 3rd gearsAw.ay from 2nd geara'tween 2nl.and 3rd gears. Difference $hould be 0.07 to 0.15 mmIt incgr':a~ proceedThickness.' .

~';s'i.,Which 91~~correct clearance',.' rI Thrust washers available\, 4.50 mm, 4.55 mm

4.60 mm, 4.65 mm" 4.70 mm, 4.75 mm4.80 min, 4.85 mm4.90 mmRetain nut for refittingSelected thicknessAs far as 4th gear

Tighten nut to l i J 95 Nm


37/58


LOCK - UP CONTROL SOLENOID / TERMINAt BLOCK - RENEWActionRemove:

BendRemove:ReleaseRemove:

Re8'ssemble

Ref. Detailend cover ,._transmission ~jfn,g;

1. nuts - termibol$> ".:;:;..'" ",', ,lead , , ,', ,2. bolt - lock - up con~olsol'enoi'd3. solenoid ' " ,4. extension leads - terminal block5. screws - terminal block6. terminal block and plate7. screws - extension lead plate

components

, '2 off ::.... ,T89S;':;u~l.~e clear of leads

2 off

Repairs 17


38/58

E A R B O X \ : 2 . ~ 5 = = = = = = 1UTOMATIC G _~p~~~~--------

180 1016

XM0693

Repairs


39/58

AUTOMATIC GEARBOX 2.5-RENEW

Special Instructionsef. Detailend covertransmission casingmainshaftcountershaftclutch1. snap ring2- end plate, discs and clutch plates

Position 3. clutch - thread of toolCompress clutch springRemove 4. snap ringSlacken toolCollect 5 . spring retainer

6. springRemove: 7 clutch piston

8. o ringsCheck components for wear and damage

The following instructions are applicable to all clutches in the gearbo)(

As necessaryf,:

o lSG 1016o 1SG 1016Use compressed aireRenew components as necessaryANote Clutch plates and discs ~hould only berenewed in complete setso rings. 'clutch plates. discs Use transmission fluid

and pistono rings .piston - clutcb " ~,;," ,spring r~.tifner and jqaP,ring to .c;1~~chspring ";,,:' " " ; , t ' : " , :i.-.:' g'lSG1016, . ' e . .. . . ~ ~j' _.I" ;~snap ring v ~~ . ~ .: ',"tool "."~'~:\"/;I: ' i '1~G 1016discs, plates and end plate' . "~ '! 'l \snap ring

9. feeler gauges

new end plate

clutch operationcomponents

~... ~.: ; . r . BetWeen top clutch plate and end platerJ Measure clearance:t st clutch - 0.65 to 0.85 mm2nd clutch - 0.50 to 0.70 mm3rd clutch - 0.50 to 0.70 mm4th clutch - 0.40 to 0.60 mmIf clearance is not correctEnd plate thickness available:-No. 1 - 2.1 mm No.2 - 2.2 mmNo.3 - 2.3 mm No.4 - 2.4 mmNo. 5 - 2.5 mm No.6 - 2.6 mmNo.7 - 2.7 mm No.8 - 2.8 mmNo.9 - 2.9 mm No. 10 - 3.0 mmApply compressed air to ports arrowed inillustration

LubricateFitPositionCompressFitRemoveFitInsert

CheckReassemble

Repairs 19


40/58

GOVERNOR - RENEWAction Raf. OatailRemove: end cover

transmission casingmainshaftcountershaft

Release: locking tabs - governorbolts - valve

Remove: 1. bolts - governor2- tabwashersgovernor

Release locking tabs - boltsRemove: 3 . bolts4- tabwashers

governor assembly5. plate

20 Repairs

:C:j(~,,~

.AUTOMATIC GEARBOX 2.5REPAJRS

, f XM0687

Spacial Instructions

3 off m 12 Nme2 off m 12 Nmf'I

~9


41/58

Action Ref. DetailRemove: end cover

transmission casingmainshaftcountershaftlock - up control solenoid

1. bolts - lock - up valve body2. valve body and separator plate3. dowels4. pin - reverse control valve cap5. valve and spring6. pin - lock - up shift valve cap7 . lock - up shift valve and springClaa" components Examine componentsLubricate componentsReassemble components

2LOCK - UP VALVE BODY ASSEMBLY - RENEW

CleanCheck:

CheckReassemble

AUTOMATIC GEARBOX 2.5S. filter7. dowels8. pipe9. circlip - drive gear10. gear11. woodruff key12. shaft13. washers14. governor valve15. circlip - weights and spring16. circlip - weights17. weigbt 'and spring assembly

comR9nentscdmi:\QI'l8f1ts for wears"'a ff'! '~" ., '.body:,." , ,Weigh.,.S I B '" ' , ; .:c O ~ F n ; ~ ';r.".~~.' '~','~-.';.'. "'\ 4 -

Clean filter in paraffin2 off

2 off

Use transmission fluid or chlorinated solventRenew as necessaryMust be free to turn in governor bodyFor wearMust be free to move when assembled to shaft

L _

2 XM0670

Special Instructions

5 off Ii! '2 Nm2 off

Use transmission fluidFor wear, renew if necessaryUse transmission fluid

Repairs 21


42/58

REGULATOR VALVE BODY ASSEMBLY - RENEWAction Ref. Detail Special InstructionsRemove: end cover

transmission casingmainshaftcountershaftclutchgovernorlock - up control solenoidand terminal block.lock - up valve body assembly1. bolt - regulator valve body fB12Nm2- regulator valve body

3. stop pin - stator shaft4 . stator shaft5. o ring e8. pin - valve cap lock - up timing1 . cap, lock - up timing valve and spring8. pin - valve cap lock - up control9. cap, lock - up control valve and spring10. bolt - regulator valve spring cap fiJl0Nm11. cap, seat, springs and regulator valve

Cleen components Use transmission fluidCheck components For wear, renew as necessaryLUbricate components Use transmission fluidReuse",ble components

22 Repairs

2

AUTOMATIC GEARBOX 2.5REPAJRS

~ '~- ~'~M:""

3 i.'i'"t~.,,.', ,

'tt'\: ., ;" .

XM0686


43/58


m14Nmfl

.: . .R E V E R S E S E LE C TO R FO R K - R E N E W

Special Instructions Action Ref. DetailRemove: gearbox housingthrottle shaft oil sealdowels

1 . reverse gear - countershaft2. bearing and sleeveRetease: 3. locking tab - selector fork bolt4. bolt - selector fork

tab washerS. fork, selector and selector hubReassemble components

fl3 off


44/58


13

. XM0698

airs


45/58

AUTOMATIC GEARBOX 2.5 SERVO VALVE BODY ASSEMBLY - RENEWAction Ref. Detail Special InstructionsFtemove: end cover

transmission casingmainshaftcpU'ntershaftclutch. ).governor 0lock - ulf control solenoidand terminal ~Ioc.klock - up valve body assemblyregulator lIal'(8 body assembly1. oil feed pipes' - servo assemblyoil baffle pl.ate.

2. bolts - 2nd / 3rd accumulatorSprit.lg eever3. accumulator spring cover

4. 2nd / lr:d accumulator springs5. bolts ~~,accumulator cover6. aceun,ufa10r cover7. Q.,ring8. sp,ring holder9. sp(injJ, .10. EeJip:':" throttle shaft11. bolts;,:-"se;;~ body

caPi::,:"" ,~" : ~t(C8 c.ontrol val~e12. . throttle'tfl f t~ , . - \S! ,&4body assembly13. separator ~18te,:;;i':"'. ". .ball and spring' '.' . ,~~,.

14. pistons . < : i . ! 15. 0 rings - pistonsshift fork shafto ring - shaft

16. servo valve17. servo return spring18. 0 ring19. plate - servo orifice

control valve20. spring and servo orificecontrol valve21. bolt - modulatorbody assembly'

22. modulator body and seperator plate23. magnet - servo bodyball and spring - main valve body

componentscomponentscomponentscomponents

2 off m 12 Nm2 off2 off2 off m 12 NmRenew clip if distorted6 off m 12 Nm

CollectRemove:CollectRemove:

:; m 12 NmCollectClaanExamineLubricateReassemble:

Use transmission fluidFor wear, renew as necessaryUse transmission fluidCAUTION Compress accumulator springs whentightening the accumulator cover boltsor stripping of bolt threads will occur

Repairs


46/58

1

XM0694


47/58


Special Instructionsef. DetailSECONDARY VALVE BODY ASSEMBLY - RENEW

end covertransmission casingmainshaft "countershaftclutch.governorlock - up control solenoidand terminal blocklock - up valve body assembIY.;l',1'regulator valve body assem~fJ;f!J~;servo valve body asseml;ly ...."'.'secondary valve bodymain valve body timing accumulators,iri/lg and valveball .. '"separator platedowels . ,. ',;\.pins - vatyes.clutch pressure control valvecomponentsreverse contrbl valve componentskickdown valve componentsspring seat

"

Separate: 1. Collect 2.3.Remove: 4.S.6.7 .8.9 .10.

11.12.13.14.

CleanExamineLubricateRea.semble

ActionRemove:

,-. J : ; / ' .~. . . .~. '.2 of"" ,3 off

3 off, accumul.ator control valve spring.lock-up cut )lalve spring,shift.timi"" valve spring

accumulator control valve compone,ntsshift timing valve components' '" -rlock - up cut valve eomponents ,":!; ..... ~~.filter ,'. _. "''l'',R' .components'''_':'' "'U~e~rans"';ission fluidcomponents" ": .,,::For wear, renew as necessarycomponents " Use tr8l1smis'sion fluidcomponents

P'


48/58


~e?WMo

XM0689

;;MA IN VA LVE BODY A SSEMBLY - RENEWAction Ref. Detail Special InstructionsRemove: end cover

transmission casingmainshattcounters haftclutchgovernorlock - up control solenoidand terminal blocklock - up valve body assemblyregulator valve body assemblyservo valve body assemblysecondary valve body

1. split pin2. clevis pin3. washers and rollers4. manual valve5. bolts - main valve body

CollectPositionRemove

To give access to bolts5 off, 10mm bolts m 12 Nm

12mm bolts f D 28 Nm


49/58

'.


Remove:

CollectRemove:

CollectRemoveCleanExamineLubricateReassemble

S. valve body7. converter check valve and spring8. oil pump gears and shaft9. separator plate10. steel balls

Gears are matched assembly3 off i A CAUTION Do not use a magnetto collect balls

11. cap - relief valve

12. spring and valve, 3. pin - orifice control valve cap14. cap - orifice control valve15. valve and spring

manual valve springrollers

16. manual valve17. screws - cover plates18. plates19. sleeves20. valves and springs21. balls and springs22. filtercomponents

componentscomponentscomponents

XM0690

6 off

eUse transmission fluidFor wear, renew as necessaryUSB transmission fluidCAUTION Ensure rollers locate in grooves inmanual valve and that chamfer of 0,1pumpdriven gear faces the separator plate

RepairS


50/58

f. , . s ~ ~


180 21862-3

XM0700

Repairs


51/58


. .Remove:

Securet. Remove: ,.SecureRemove: 2-Drift out 3.4.Remove: 5.6.7.aC.leanImmediatelyexamine

L ASSEMBL Y - RENEWRef. Detail Special Instructions

In soft jawed vicei!18G 2 and a suitable thrust buttonUse soft jawed vice'0 off iii 129 Nm LH. threade Use II soft driftUse a soft drift

Use chlorinated solventUse transmission fluidFo~.wear, renew as necessary

Continued. , ..

end covertransmission casingmainshaftcountershaftgovernorlock - up control solenoidand termi,nal block'lock " u t i valve body assemblyreQ1tlato~ valve body assembly'servo'yaive' body assemblysecon#.ary valve bodymain va'lv.e'bodyditferen,' ~ssemblydiffere sS'8mbly,differeriti.r "eatingsditf.rei\~ :.~s~bly - vicecrow, '. 6eUn,'iic.ebolts: ; 1 , ' ,.o,wn~",heeldiff.t.~:ptla'i :aj:$'.~bIY, r: ,viceroll pin ~'" ,"1{- ,pinion sh8,tt~:.::, ,pinion thrust washers f:pinion side gearsspring ring - differenti.l~1 .,speedometer drive gear'" differentialcomponentslubricate bearings ", -.',components

":,


52/58

: : A , i .U ~ T ~ O ~ M :A ~ T ~ I ~ C G :E = A ~ R - = - B _ O _ X 2 _ .5

17

XM0701

32 Repairs

18G 1396


53/58

FrtPlaceFitPositionMeasure:Adjust


FrtSecureFit:

9. differential gears. pinions andthrust washers to carriergears To align pinions and thrust

washers with driliings in carrierUse a soft drift. Do notfit roll pin at this stagei!l8G 1396 J.Note Largest bearing is fittedspeedometer drive gear sideOn suitable Vee blocks

10. pin ion shaft11. differential bearings carrier12. differential assembly13. drive shafts14. D.T.I. gauge15. backlash-of both pinion gears Record figures obta inedn Correct backlash is 0.05 to 0.15 mm

By means of thrust washersn Thrust washers available0.70 mm. 0.75 mm0.80 mm. 0.85 mm0.90 mm. 0.95 mm1.00 mrn, 1.05 mmA CAUTION Thrust washers selected must beof equal thickness

backla~h

selected thrust washers16. pinion shaft17. speedomete~ drive gear18. .',snap rin9.' .

, ),-,

Use a new roll pinA CAUTION Ensure snap ring abuts againstroll pinChamfer on inner radius of gearfaces the carrier6 1 129 Nm. Bolts have LH.thread and must be tightened progressively

19. gear - earrier;


54/58


180 1527

XM0661

34 Re


55/58

AUTOMATIC GEARBOX 2.521. differential assembly

22 -23.

In torque converter housing~Note If new bearings have been fitted,new outer races will need to be fittedin transmission casing and torqueconverter housing

outer bearing track - transmission caseshims - transmission caseshims 2 off, total thickness of shims must

equal 2.15 mmF " r t 24. shims and outer bearing track25. transmission casingTighten 2&. securing boltsRotate diff .rentfalF " r t 27. o 18G 1527 - shaft28. o MS 103 - 0 l8G 1527Rotate differential

Use a new gasket fitted dry, m 45 Nm.To settle 'bearingso 18G 1 527 and a socket barANote Torque required to turn differentialshould be:n Existing bearings 2.5 - 3.6 NmNew bearings 2.7 - 3.9 NmI f reading is outside limits, select alternativethickness shim.One shim thick.ness will adjust figure by 0.4 Nmn Shims availableA 0.90mmB 0 .95 mmC 1.00mmo 1.05 mmE 1.10 mmF", 1.15 mm'G lo ".20 mmH".1.26. mm~,,:. 1.30mmoJ 1.35 mmReq",lred to rotate differential

~ .1, 'O"" ' .e, /'

' .v ' . . ,. 'I:.... ~FitRecheckReassemble

selected shimstorquecomponents


56/58

.AUTOMATIC .GEARBOX 2.5

TORQUE CONVERTER HOUSING - RENEWActionRemove:

ReleaseRemove

Ref. Special Instructions

Detailend covertransmission casingmainshaftcountershaftclutchgovernorlock - up control solenoidand terminal blocklock - up valve body assemblyregulator valve body assemblyservo valve body assemblysecondary valve bodymain valve body

1. differential assembly2. bearing outer tracklocking tab - selector shaft bolts

3. bolt m12Nm

Repairs


57/58


CollectRemove

4. tab washer5. connector6. shaft7. oil seal8. plugs - converter housing9. sealing washers

banjo bolt - oil' ,hosesealing washerspipe

f15 off, fi ) 18 Nm5 off. e6 J 18,Nm',.~ off. e

18G 284-12

~.-12@-1318G284-7M0664

Use D18G 284 and B l8G 284-7Use 0 l8G 284 and D l8G 284-12f1Use chlorinated solventImmediately, use transmission fluidFor wear, renew as necessary

Remove: 10. countershaft bearing11. oil barrier plate12. mainshaft bearing13. mainshaft oil seal

componentsbearingscomponentsconverter housing oilwayscomponents Ensure snap rings are correctly located

on bearings. Lubricate mainshaft oilseal with petroleum jelly

CleanLubricateExamineCleanReassemble


58/58


, ., ' ' ( . . " , . o ! '

S E L E C T O R SUDE INDIC4 T R ~ ~ / ! g I N E W")'-i~ - ',I.i: ..:_' ,~Action R.f. Detail Sp.~i.1 Instructions'.selector leve1. screw - sele.Ctol'handl.2. selector hiVIdle - lever3 graphic 'panel - console

4. slide indicator - graphic panelcomponeots

MoveRemove To position NLever at rear edge

Reassemble Ensure tree action of indicator

XM0785

Documents

08 Auto Gearbox