Overhaul

NOTE: Component identifier numbers used in the following illustrations relate to specific steps in the procedures below.





Disassembly
1. Undo the securing screws and separate the pump from the partition plate (lightly tap the side using a plastic hammer).
The seals and guide pins normally remain in the partition plate.
The pump can be dismantled by removing the pump impeller (A) and annulus (B).
2. Check the following:
- That the lugs inside the pump impeller are not bent.
- That the teeth on the pump impeller and annulus are not worn.
- That contact surfaces are flat and even.
3. Remove the compression spring and the relief valve from the partition plate.
4. Pick out the circlip from its groove and remove the entire plate assembly with brake C and the Belleville washer.
5. Check groove width between the seals and seal grooves. Measure using a feeler gauge. Clearance must not be greater than 0.17 mm.
6. Check the seal between clutch A and the partition plate cylinder.
a. Remove the seals from clutch A.
b. Place the seals in the partition plate cylinder where they normally seal.
c. Measure the distance in the seal attachment. If distance is greater than 0.50 mm, the seals should be changed. If this does not help, the partition plate cylinder must be changed.
d. Install the seals to clutch A.
7. Press out plunger C by screwing in two opposite screws from the pump side.





Assembly
1. Assemble the pump housing so that the marks on the pump impeller and pump ring gear point up.
2. Tap the two guide pins into the partition plate using a plastic hammer.
3. Install the complete relief valve for the torque converter.
4. First install the valve into the cover and fully insert it into the partition plate, lubricating with Vaseline if necessary.
5. Install the compression spring into the recess in the pump.
6. Place the partition plate on the pump housing and align it.





7. Press the partition plate and pump housing towards each other, turn upside down and attach using the screws.
Wrench size = TORX socket - TX27
Tightening torque: 10 Nm (7.3 ft. lbs.)
8. Check that the torque converter relief valve moves freely.
9. Using tool No. 87 91 725, or equivalent, check that the pump can rotate.
10. Install the three seals to the partition plate hub and hook them into each other.
11. Install O-rings to plunger C and grease them using Vaseline.
12. Press the plunger into the partition plate.
13. Install the entire plate assembly into brake C. Start with the outer plate. Place the Belleville washer so that the raised outer edge faces upwards.
Then install friction plates and outer plates alternately. There should be three friction plates.
14. Install the final plate and secure using the circlip.





15. Check and adjust clearance in brake C.
a. Install circlip (Selected thickness = 1.1 mm (0.043 inch)
b. Install fixture tool No. 87 91 808 and dial gauge tool No. 78 40 622, or equivalents.
c. Place the gauge tip tool No. 87 91 85, or equivalent. against the final plate and set the dial gauge to "0".
d. Lift the entire plate assembly and read the
Clearance on the dial gauge. Clearance should be 1.4-1.6 mm (0.05-0.06 inch).
e. If the reading deviates from the specified value, a thicker or thinner circlip should be used.

CAUTION:
^ If new plates have been installed, they should be removed after this check and be placed in automatic transmission fluid for a short time.
^ If plates are dry, they may burn.