To assemble

Transfer the outer plugs to the new housing. Carefully remove the old sealing compound from the gearcase's sealing surface using a gasket scraper.
Heat the bearing seat with a heat gun and tap the roller bearing into the torque converter housing using 87 90 461 SLEEVE, BEARING RING and 83 90 189 DRIFT . Press in the bearing with the text facing downwards until it reaches the bottom of the torque converter housing. The side of the roller bearing forms the bearing race of the output shaft's thrust bearing. Remove the sealing ring before heating and fit a new ring once the bearing is in place.

Fig 1: Illustration For Step 2
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Heat the bearing seat for the differential bearing race in the torque converter housing. Fit the bearing race. Make sure the bearing race is all the way home.

Fig 2: Illustration For Step 3
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Fit the oil duct plate and the three magnets. Blow the pipe clean, apply vaseline to the ends of the pipe and fit the pipe using a splinter-free plastic mallet. Take care not to bend or damage the pipe. Fit the pipe clip.
Lift out the output shaft complete with thrust bearing and bearing race.

Fig 3: Illustration For Step 5
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Lubricate the bearings with automatic transmission fluid.

Fit the differential and fit the torque converter housing. Only fit every other bolt. Fit a 87 92 483 TORQUE WRENCH and 87 91 337 DRIVER, MEASURING DIFFERENTIAL BEARING TORQUE to the differential housing (file down the key slightly if the tool does not fit the differential shaft). Turn until the reading is stable.

Fig 4: Measuring Differential Bearing Torque

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IMPORTANT: Inspect the inside of the differential housing for damage. Check also the surfaces of the drive shafts.

Tightening torque 24 Nm (18 lbf ft)

Measure the prestress. Start value:

TORQUE SPECIFICATION

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 gearcase 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 housing and lift out the differential.
Align the plates using a screwdriver and fit the output shaft complete with clutch unit C3. Make sure that the shaft falls into place at the same height as the intermediate gear. Check that the shaft and gear rotate freely. Fit a bolt to the shaft to rotate it.

Fig 5: Illustration For Steps 10-11
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Fit the thrust bearing race and the thrust bearing on the output shaft unit.
Fit the differential unit.

Fig 6: Illustration For Steps 12 & 14
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Fit the differential housing unit.
IMPORTANT: Inspect the inside of the differential housing for damage. Check also the surfaces of the drive shafts.
Clean the sealing surfaces on the gearcase and the torque converter shell. Use Cleaning agent, Loctite Super Clean 7063. Keep surfaces free from grease.
Fit a new seal into the gearcase and apply an approx. 1 mm thick bead of 87 81 841 Silicone flange sealant to the gearcase as illustrated. Fit the torque converter housing.
Apply Thread locking adhesive, Loctite 577 to the inside bolts. Fit the bolts (different lengths). Tighten the bolts.
Tightening torque 25 Nm (18 lbf ft)

Fig 7: Illustration For Steps A, B, C & 16
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Clean the magnetic surface on the drain plug and fit it with a new gasket.
Tightening torque 40 Nm (30 lbf ft)
Turn the gearcase so that the shaft points approx. 45° downward. Apply vaseline to the O-ring for the oil pump unit. Align the plates using a small screwdriver. Insert the thrust washer greased with vaseline into brake B1.

Fig 8: Illustration For Step 18
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Fit freewheel F1 and the bearing race for brake B1 and B2 to the oil pump unit. Lubricate the thrust washer for F1 with vaseline and fit it.

Fig 9: Illustration For Step 19
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Place the oil pump unit so its bolt holes are aligned with those in the gearcase. Press the pump unit in place carefully. Tighten the bolts carefully and alternately.
Tightening torque 25 Nm (19 lbf ft)

Fig 10: Illustration For Step 20
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Turn back the gearcase 45°
Check that the turbine shaft has an end play of 0.37 - 0.9 mm. Use 78 40 622 DIAL GAUGE and 87 90 727 BRACKET, DIAL GAUGE .

Fig 11: Identifying Dial Gauge
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Change the torque converter seal, see ADJUSTMENT/REPLACEMENT Torque converter seal.
Fit the torque converter. Use 87 91 766 GRIPPING TOOL, TORQUE CONVERTER Fit 87 92 574 HOLDER .

Fig 12: Illustration For Steps 24 & 26
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Make sure the torque converter has been fitted in the correct position and lay a steel rule on the mating face of the torque converter. Measure the distance between the mating face and the drive plate contact surface on the torque converter. The distance must be at least 15 mm.
Remove 87 91 766 GRIPPING TOOL, TORQUE CONVERTER .
Fit new drive shaft seals. Use 83 90 122 DRIFT .

Fig 13: Identifying Gripping Tool
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Remove the gearbox from the stand. Remove the holder from the gearbox.
Plug in the connectors to the gear selector and speed sensors.

Fig 14: Illustration For Step 29
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Fit the gearbox in the car. See TO FIT , Complete automatic transmission. Remember to clean the oil cooler with 87 91 824 FLUSHING EQUIPMENT .