Torque converter shell: Fitting

Heat the bearing seat for the differential bearing race in the torque converter shell. Fit the bearing race. Make sure the bearing race is all the way home.

Fig 1: Illustration For Step 1
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Heat the bearing seat using a hot-air gun and fit the roller bearing into the torque converter shell with the text face down until it bottoms in the torque converter shell. The side of the roller bearing will be the bearing race for the thrust bearing on the output shaft.
Place the three cleaned magnets on the oil channel plate. Apply thread locking compound 74 96 268 to the bolts and fit the oil channel plate.
Tightening torque 5.5 Nm (4 lbf ft)

Fig 2: Illustration For Steps 3-4
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Fit the pipe using a splinter-free plastic mallet. Take care not to bend or damage the pipe. Fit the pipe clamp.
Lubricate the bearings with automatic transmission fluid and fit the differential into the gear case without the crown wheel.

Fit the torque converter shell. Fit only every other bolt.

Tightening torque 25 Nm (18 lbf ft)

Measure the prestress on the differential with a dynamometer 87 92 483 TORQUE WRENCH and drift 87 91 337 DRIVER, MEASURING DIFFERENTIAL BEARING TORQUE . Rotate until the value has stabilized. Start value:

Fig 3: Measuring Prestress On Differential

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BEARING PRESTRESS VALUE SPECIFICATIONS

New bearing	1.0 Nm (7 lbf ft)
Refitted bearing	0.5 Nm (3.5 lbf ft)

If the prestress is not within specified limits, remove the differential and bearing race from the gear case and change shim. If the reading exceeds the specified value, change to a thinner shim. If the reading is lower than the specified value, change to a thicker shim. Shims are available between 1.0- 1.90 mm in small intervals.
Remove the torque converter shell and lift out the differential.
Heat the crown wheel with a hot-air gun for about 5 minutes.
Fit the crown wheel on the new differential.

Fig 4: Illustration For Steps 10-11
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Fit new locking washers and fit the bolts.
Tightening torque 100 Nm (74 lbf ft)
Bend up the locking washer against the flat surface on the bolt head.
Fit the differential unit.

Fig 5: Illustration For Steps 13, 15-16
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Clean the sealing surfaces on the gear case and torque converter shell. Use cleaner 30 02 599. Keep the surfaces free from grease.
Fit a new seal in the gear case.
Change the oil strainer in the gear case
Apply a bead of flange sealant 93 21 795 approximately 1 mm wide to the gear case as illustrated and fit the torque converter shell.

Fig 6: Illustration For Step 17
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Apply thread locking compound 74 96 284 to the internal bolts. Fit the bolts (different lengths). Tighten the bolts.
Tightening torque: 25 Nm (18 lbf ft)

Fig 7: Installing Bolts
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Fit the oil temperature sensor cover plate with nut, washer and bolt.
Tightening torque, bolt 25 Nm (18 lbf ft)

Tightening torque, nut 10 Nm (7 lbf ft)

Fig 8: Illustration For Steps 19-20
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Fit the cover plate
Clean the magnetic surface on the drain plug and fit it with a new gasket. Fit the remaining outer plugs.
Turn the gearbox with turbine shaft 45° downward.
Apply petroleum jelly to the O-rings for the oil pump unit. Align the disc package with a small screwdriver. Fit thrust washers lubricated with petroleum jelly on brake B1/B2.

Fig 9: Illustration For Step 23
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Fit freewheel F1 and the bearing race for brake B1 and B2 on the oil pump unit. Lubricate the bearing race for F1 with petroleum jelly and fit it.

Fig 10: Illustration For Step 24
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Place the oil pump unit so its bolt holes are aligned with those in the gear case. Press the pump unit in place carefully. Tighten the bolts carefully and alternately. Make sure the turbine shaft has an axial clearance of 0.37- 0.9 mm.
Tightening torque 25 Nm (19 lbf ft)

Fig 11: Illustration For Step 25
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Turn back the gear case 45°.
Change the torque converter seal. See ADJUSTMENT/REPLACEMENT , TORQUE CONVERTER SEAL .
Fit the torque converter. Use holder 87 91 766 GRIPPING TOOL, TORQUE CONVERTER . Fit locking device 87 92 574 HOLDER .

Fig 12: Illustration For Step 28
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Fit new drive shaft seals. Use drift 83 90 122 DRIFT .

Fig 13: Installing Drive Shaft Seal
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Lift down the gearbox from the stand and remove the holder.
Fit the GEARBOX in the car. See ADJUSTMENT/REPLACEMENT , fitting gearbox assembly.