To Fit Intermediate Shaft
To fit intermediate shaft1. Fit the lipped washer, needle bearing cage and thrust washer over the end of the intermediate shaft and fit the intermediate shaft in place.
2. Fit the two thrust washers and needle bearing cage in the short end of the intermediate shaft in the center of the hub.
3. Fit the thrust washer on the engine shaft and center it.
4. Fit the engine shaft, turning it at the same time. If correctly fitted, the shoulder on cylinder E should be slightly higher than the edge of the sun gear shaft (approx. 1.5 mm) ..
5. Fit clutch A.
6. To ensure correct assembly, check that the distance between the turbine shaft and the engine shaft is about 22 mm (0.9 in.).
7. Fit brake band C1.
8. Fit clutch B, twisting it back and forth to ensure that the plates engage with each other. If correctly fitted, cylinder B should engage with the recesses in the drum until a gap of only about 1 mm is visible between the drum for clutch A and clutch B.
9. Fit the partition plate with brake C and the pump without the one-way clutch for 2nd gear.
10. Fit the shim holder and the appropriate shims on the hub of the partition plate.
11. Fit the 2nd gear one-way clutch into the intermediate plates for brake C so that the inner teeth are in contact with the washers.
12. Turn the one-way clutch outer ring to check that all intermediate plates rotate with it, ensuring that all are engaged.
13. Tighten the brake band adjusting screw slightly to secure cylinder B. Turn the gearbox one quarter turn.
14. Fit the entire assembly (pump, partition plate and 2nd gear one-way clutch) in the gearcase, twisting it back and forth while pressing it inwards.
Make sure that the one-way clutch does not drop out of the plate assembly.
15. If correctly fitted, the lipped washer should be in contact with the gearcase and deflect when the pump body is pressed.
16. Secure the partition plate by means of its eight screws. Torx bit size T27.
Tightening Torque: 10 Nm (7.4 ft.lbs.)
17. Loosen the brake band.
18. Adjust the brake band by tightening to 10 Nm (7.4 ft.lbs.) and then backing off 1-1/4 turns.
Turn the gearbox one quarter turn.
19. Fit the differential in place.
20. Fit the torque converter casing and a new gasket.
Tightening torque: 23 Nm (17 ft.lbs.).
21. Turn the gearbox one quarter turn.
Fit the torque converter, using two mounting grips P/N 87 91 766, by twisting and pressing it until it bottoms.
22. Fit the gearbox in the car. See Service Manual 4:2 Automatic transmission.
23. Fill the gearbox with oil.
24. Check the oil level.
25. Adjust the kick-down position as described in the enclosed attachment. This is a reproduction of a Plastic Coated card issued several years ago. Make certain tool P/N 87 91 980 has been modified per PSI 10/90-0035 (Sec. 1, p. 4) copy also.
26. Check the positions of the gear selector lever.
27. Add 5 fl. oz. (1.5 dl) of LUBEGARD additive.