A/T - Harsh Engagement Into `D' or `R'

Group: 27

Number: 240

Date: November 1989

SUBJECT:
HARD TRANSMISSION ENGAGEMENT INTO "D" OR "R"
AUTOMATIC TRANSMISSION 722.4

If the shifting process is delayed and accompanied by harsh engagement with a grunting noise when placing the selector lever into positions "D" or "R", the following transmission parts should be replaced:

when shifting to "D", brake band B2
outer plates carrier K2 (exceptional cases only)

when shifting to "R", outer plates LB3

NOTE:
See Diagnostic microfiche group 27 "Survey of Current Topics" for additional modifications.

Procedure

1. Remove transmission, see job no. 600.

2. Partially disassemble transmission, see job no. 27-640, and 690 if required.

3. Remove clutch K1, brake band B1, gear assembly, clutch K2 and brake band B2.





4. Place new brake band B2 onto clutch carrier K2. Press band together and measure distance "A" (Figure 1). If dimension "A" is less than 5 mm, carrier K2 must be replaced. If the center of the circumferential surface is worn where the groove pattern is no longer visible, the carrier should also be replaced.








5. With transmission end numbers below 316257, inspect ball check valve (23) in front cover for proper seating or damage, replace if necessary. Also install new retaining plate (24) (Figure 2). See job no. 27-630.

Note:
Immerse new ball check valve in water approximately 1 hour prior to its installation.

6. To do so, remove and reinstall piston LB3.





7. Check lip seal ring for damage (16, 17) and replace if necessary (Figure 3).

8. Install piston LB3 of multiple disc brake in front cover.

9. Install the 20 return springs. Replace seal rings for K1 with Teflon rings.

10. Replace seal rings for supporting flange K2 with Teflon rings, install new brake band B2 in transmission, if required K1, K2 free play 0.9 - 1.2 mm.

11. Place clutch K2 on gear assembly.

12. Carefully insert gear assembly into transmission housing, and reassemble.

13. Install friction and steel plates as required on brake LB3.

Note:
Nitrided steel plates for LB3 are used in production beginning with transmission no. 440103, for replacement transmissions as of number 200218.





14. Measure release clearance "L", 1.5 - 2.0 mm, of brake LB3 and adjust if necessary (Figure 4).

15. Measure release clearance of brake band B2 and B1 and adjust if necessary.

16. Reassembly transmission.





Tightening Specifications





Parts Information

NOTE:
For adjustment of B1 the various sizes of washers have to be ordered. For adjustment of B2 the various sizes of pins have to be ordered (see parts microfiche). For the adjustment of K1, K2 the various sizes of steel plates should be ordered.

REPLACEMENT OF BAND 2 (Job No. 27-640) REQUIRES PRIOR ZONE AUTHORIZATION





Special Tool Information





In Case of Warranty