08 Auto Gearbox
-
Upload
whitelion58 -
Category
Documents
-
view
222 -
download
0
Transcript of 08 Auto Gearbox
-
8/3/2019 08 Auto Gearbox
1/58
AUTOMATIC GEARBOX 2.5CONTENTS
Description and Operation PageAutomatic gearbox components 3General 5Torque converter 5Gearbox 7Hydraulic system 8Differential 14
Adjustments PageAutomatic gearbox - drain and refill 1Hydraulic engagement - check console fitted 2Selector cable - adjust 3Hydraulic engagement - check console removed 4Kickdown cable - check/adjust 5
Repairs PageKickdown cable - renew 1Starter inhibitor/reverse light switch - renew 2Selector cable - renew 3Gearbox and torque converter - renew .4End cover - renew 7Gearbox casing - renew 8Mainshaft - renew 12Countershaft - renew 14Lock- up control solenoid/terminal block - renew 17Clutch - renew 18Governor - renew 20Lock - up valve body assembly - renew 21Regulator valve body assembly - renew 22Reverse selector fork - renew 23Servo valve body assembly - renew 24Secondary valve body assembly - renew 26Main valve body assembly - renew 28Differential assembly - renew 30Torque converter housing - renew 36Selector slide indicator - renew 38
NOTESSymbols have the following meanings:;. ;:;WARNINGii. = CAUTION;. = NOTE= TORQUE WRENCH FIGURE
E ! = SERVICE TOOLm = FASTCHECK TOOL~ = NON REUSABLE ITEMri = INFORMATION
-
8/3/2019 08 Auto Gearbox
2/58
AUTOMATIC GEARBOX 2.5D ESCR IPTIO N A ND O PER ATlO N
2 Description and Operation
-
8/3/2019 08 Auto Gearbox
3/58
AUTOMATIC GEARBOX 2.51. Torque converter 49. Governor assembly2. 0 ring 50. Main valve body3. Differential oil separator plate bearingseal 51. Main valve body ..99. Reverse idler gear. ,4. Locating dowel 52. Converter check 100. Gasket5. Oil seal valve and spring 101. Gearbox casing
S. Bearing.~.s3. :9il pump gears . 102. Reverse idler shaft7. Selector shaft oil 1, '1)4. . Oil pump shaft 103. Retainerseal -. 55. Stator shaft'~ 104. Throttle lever8. Converter housing ' :S6.0 ring' assembly9. Oil feed hose .57~Regulator valve 105. Throttle shaft10. Banjo bolt assfmbly 106. Parking pawl11. Sealing washers 58:Cii~lip . assembly12. Throttle lever 59. :,Ne.edlebearing 107. Breather cap
assembly S O . Sealing rings . 10a. Breather13. Oil pipe 61. Separator plate':>, ?" 09. Lifting eye14. Banjo bolt 6 2 . Lock up valve, 110. Cable retainer15. Sealing washers assembly , 'i'l'~ 1. Tabwasher16. Oil baffle plate .~. Mounting plate .c ' ; ". ~.: . '11-2. Shouldered collar17. Countershaft bearing 64. Connector blockf'\j13. Thrust washer18. Counters haft ,*" ,6S;',Connector leads ~n4.Mainshaft 1st gear19. Differential pinion .,. 86. Dipstick and tube 115. Needle bearing
assembly ..' ':t,:"
-
8/3/2019 08 Auto Gearbox
4/58
AUTOMATIC GEARBOX 2.5DESCRIPTION AND OPERATION
CUTAWAY OF GEARBOX1. Torque converter2. Valve bodies3. Mainshaft 2nd gear4. 2nd clutch5. 4th clutchS.Gearbox breather7. 4th gear8. Mainshaft reverse gear9. Mainshaft 1st gear10. 1st clutch11. Parking gear
12. Countershaft 1st gear and one wayclutch assembly
13. Countershaft reverse gear14. Countershaft 4th gear15. Countershaft16..Countershaft 2nd gear17. Countershaft 3rd gear18. 3rd clutch19. Differential assembly20. Governor assembly21. Mainshaft
4. Description and Operation
-
8/3/2019 08 Auto Gearbox
5/58
AUTOMATIC GEARBOX 2.5
GENERAL
The assembly comprises a torque converter coupled to a dual shaft gearbox, The gearbox has four forwardspeeds and one reverse: gear changes will occur automatically depe.nding upon selector position, vehicle roadspeed and throttle position. The selector has six positions:- Par~ 'P', 'Reverse 'R', Neutral 'N', '04', '03and '2'. The torque converter and drive plate assembly is splined directly on to the end of the enginecrankshaft and the gearbox mainshaft and incorporates a 10ck-.CI.p,t.IlIe.qhanismwhich is operated hydraulicallywith the timing of the loc~-up ~oPtil1:!,~~,~dt:$yelectronic ecntret. The n'iainshaft and countershaft run parallelto each other and carry the" clutcp..8s,;gears and parking gea,r.The '04' position gives 1-2-3-4upshift$and 4-3-2-1 down$hiftSL tlfe '03' position gives 1-2-3 upshifts and3-2-1 downshifts. The remaining posit.rids '2'. In this gear s~lection, the car will move off from rest insecond gear and remain in this gear with'n~ upshifts or downs:' . Second gear gives maximum engine brakingand can be used for driving on slippery or loose road surfac~' "", ;"
9 .." ... "
All gears run on needle roller bearings except 2nd gear on the'ountershaft which is splined directly to theshaft. All gears, except reverse on the,mainshaft are in constant. mesh with their corresponding gear on thecountershaft. Reverse gear is setected rnanuallv via a selecto .,fork. Orive is transmitted from the mainshaftto the countershaft by the engagement' of clutches or reverse idler gear.
TOROUE CONVERTERThe torque converter is of 'the three efement type comprising an impeller, stator and turbine andincorporating an electroni~~t,;controlled'l.oek-uP mechanism which locks the turbine to the impeller in '0'range, depending on vehicl1r1sp', ~~'throttle pOSition. The stator is splined to the stator shaft whichapplies an additional forceo,h"'.:iil'41atprvalvejclu'ting acceleration. Thi$ increases line pressure andprovides an additional claif,ping p a~'onthe 'clutch plafes. .
I \ _ ~'-.."
The impeller is driven by the engine.'l' ,~ ~,
The stator is situated between the impeller "a'nd: the turbih!l'' 'and incorporates a one-way clutch. The turbinedrives the gearbox via the mainshaft. ., " -, ."'The impeller, stator and turbine are contained within the .torque converter casing. Transmission fluid isunder pressure within the torque converter casing while' the engine is..running. Power is transmitted by theimpeller. As the impeller rotates, the impeller blades pick up fluid"which' is directed by centrifugal forceagainst the blades of the turbine. The fluid striking the turbine blades cabses the turbine to rotate which,in turn, rotates the mainshaft of the gearbox. Fluid leaves the turbine blades and is directed against thestator which redirects it back to the impeller. The blades of the stator are set at an angle to direct thefluid against the impeller is such a way that optimum rotational assistance is given to the impeller.
Description and peranon 5
-
8/3/2019 08 Auto Gearbox
6/58
AUTOMATIC GEARBOX 2.5DESCRIPTION AND OPERATION
1
2 XMOSS9"...~t:l.: :. l'f'2. TurbineTOROUE CONVERTER1. Impeller 3. Stator
The one way (sprag) clutch'preveVt$:Ule stat~r trolt' m~liing' backwards so that accurate redirection of thefluid can be achieved. When the':en,glne'iis Idi~"g,th~impeller blades throw out very little fluid thus theturbine does not rotate. As impell~r ~J:I"ed,.iqcr,a~tis however, the blades throw out more fluid, the turbinebegins to rotate and increases $p,eed,asAhe1eqgine/impeller speed rises. As turbine speed increases, thestator begins to rotate and fluid is ~ir~ted,6a,dk to the impeller. When turbine speed aproaches impellerspeed, centrifugal force in both elements. ,is almost equal and all three elements are moving at almost thesame speed: this is known as the 'coupling point' of the converter.
Torque multiplication or drive ratio varies until a 'one to one' coupling point is reached. To achieve thepower required to climb a'hill the .driver depresses the accelerator pedal and the torque converter reacts byincreasing torque multiplication. When driving on a flat road at cruising speed. the power required is lessand torque multiplication remains at one to one.Lock-up mechanismWith a conventional torque converter, there is always a certain amount of slip between the impeller andturbine. This can contribute to a reduction in fuel economy' especially during high speed cruisingconditions. This is eliminated in this gearbox by a Io,ck-up meehantsm, Lock-up is achieved by a lock-uppiston incorporating a friction lining. When the pistGfI is a,pp!ied"ilv hydraulic pressure, the frictionlining contacts the impeller eliminating sliQ betwe:en the turbjne and impelier. Lock-up is only functionalin 2nd gear and above with '04' select"d. 'depending on coolant temperature. vehicle speed and throttleopening. This system is controlled by governor and throttle pressure and by a lock-up control solenoid valveactivated by the ECU. .EngagedWhen throttle opening. vehicle speed, coolant temperature and governor pressure exceed certain limits. fluidbetween the converter cover and port C piston is discharged, converter pressure enters through the inlet andexerts pressure on the lock-up piston engaging the lining with the impeller. The effect is to by-pass theconverter, thereby placing the torque converter in direct drive.DisengagedWhen throttle opening. vehicle speed, coolant temperature and governor pressure fall below certain limitsconverter pressure enters through port E and moves the lock-up piston away from the impeller disengaging thelining. The lock-up mechanism is now released and the impeller and turbine can rotate at different speeds.Port 0 carries fluid to the cooler.
6 . Description and Operation
-
8/3/2019 08 Auto Gearbox
7/58
AUTOMATIC GEARBOX 2.5
:1'-
LOCK -UP MECHAN/SM .:~A Engaged1. Lock-up piston
B Disengaged2. Damper spring
G E A R B O X~., "i.
1st Clutch " ,< t . ': " '~ : " ': " " 'The 1st clutch is mounted on the mainshaft andk&"i~8VAlydraulic pressure to lock the mainshaft 1stgear to the mainshaft. The mainshaft 1st gear drive~dhe'~i1untershaft 1st gear via a one way clutch.2nd ClutchThe 2nd clutch is mounted on the mainshaft between the 2nd gear and 4th clutch. The clutch is applied byhydraulic pressure and locks the mainshaft 2nd gear to the mainshaft in 2nd gear of '04', 03' and '2'. The1st clutch remains 'ON' in 2nd gear whilst the one way clutch freewheels to prevent the transmission fromlocking up3rd ClutchThe 3rd clutch is mounted on th..cou.n~rsha.'t between the crown wheel and countershaft 3rd gear. The clutchis applied by hydraulic pre5sunt."id)1~ks th.e cot.l!"tershaft 3rd gear to .the countershaft in 3rd gear of '04'and '03'. The 1st clutch,rem~i"s'ON' in 3,d. gear:.aridthe one .way clutch freewheels to prevent thetransmission from locking up! . . ..",4th ClutchThe 4th clutch is mounted on the mainshaft between the 2nd clutch and mainshaft 4th gear. The clutch isapplied by hydraulic pressure and locks the mainshaft 4th gear to the mainshaft in 4th gear. 4th clutch isalso applied when 'R' reverse is selected, mainshaft reverse gear being integral with the mainshaft 4thgear: power is transmitted from the reverse gear to the final drive via the reverse idler gear, countershaftreverse gear and the countershaft. The one way clutch freewheels to prevent the transmission from lockingup.One-way ClutchA sprag type, one-way clutch is fitted between the countershaft 1st gear and parking gear. When both gearsrotate in the same direction, the clutch sprags lock the gears. When the gearbox upshifts from first tosecond, the countershaft turns faster than 1st gear, the parking gear turns in the opposite direction andfreewheels. This also occurs in 2nd and 3rd gears with the gearbox in 3 and also in 2nd: 3rd and 4th gearswith the gearbox in O .Revers. gearWhen 'R' is selected, the reverse selector fork engages with the countershaft reverse gear. Power flows viathe mainshaft reverse gear, reverse idler gear and countershatt reverse gear. Engagement of the selectorfork is assisted by a servo whilst disengagement is spring assisted.
-
8/3/2019 08 Auto Gearbox
8/58
"AUTOMATIC GEARBOX 2.5DESCRIPTlON AND OPERATION
HYDRAUUC SYSTEMThe hydraulic control block comprises of the oil pump which is driven from the torque converter, and a valvebody. The valve body consists of the main valve body, regulator valve body, sscondarv valve body, servo bodyand lock-up valve body. The lock-up control solenoid valve is attached to the modulator valve located in thetop of the servo body.Hydraulic pressure produced by the oil pump is regulated by the pre~sure regulator valve and directed to theclutches to produce the desired gear ratios.; ,",.HYDRAULIC VALVES f',r';'~:4;';(
"~" . . . ~: -Pressure Regulator Valve ~' y' ' .. ,,'The regu~ator valve controls line pressure to prevent f1uctu~ti~(.:;, c t I)y -yariations in pump speed. Ashaft, sph.ned to the stator at one end, operates a lever whlch';a " 'afor,c. on the regulator valve.During hard acceleration and hill climbing, before convertf)h,ceVa < r i g point is reached, stator pressure isat its greatest, the regulator valve will raise the pressure pro d:tlilf4ncreased clamping load on theclutches preventing slip. .; '~ < , j , : ~ ; :
. ~., , "~~~~ , ~This valve regulates lubricating fluid p(ess!J'r!l;-10the e ::~.ijrshaft. When the pressure increases, thespring is compressed and the valve' opense\c~.au~'in~~~Etxciesspressure.
1;'~'A:.: : :~:~
-
8/3/2019 08 Auto Gearbox
9/58
AUTOMATIC GEARBOX 2.5
P3
/1.;'i, ' < ~ I ' 1 ' c
~1l...."I:I" '--t:~:::;: .~:(' .:(,;; '" ."1-2, 2-3 AND 3-4SHIFlrVALVES1, 1-2 Shift v.lve "" ' . ; " " ; ' l > : 'k2. 2-3 Shift valve'3. 3-4 Shift valve'4. 3-2 Timing valve
XM06745. Clutch pressure controlP1 Governor PressureP2 Throttle Pressure 'A'
, < I ' , . . . . _ ' , ' . 1 ' 3 - Throttle Pressure'S'; ; _ .; . c : ,"':".~4 ',~,Clutch Pressure Control )lalve 'f " " " :1This valve controls line pressure dependant upon' throtll pr'~$ure :A', Clutch pressure to the 1-2 shiftvalve is reduced during low throttle pressure conditions alleviating shocks in gear shifting.~ .3-2 Timing ValveThe 3-2 timing valve prevents a 3:-2 shift occuring when there is only a small increase in throttle pressure'A.'. When throttle pressure reaches a certain level, the 3-2 timing valve moves allowing throttle pressure'A' to the 2-3 shift valve.Shift Timing Valve and Timing Accumulator .PistonIn '2', second clutch pressure moves the shift timing valve (4) thus overcoming spring pressure. This closesthe governor pressure passage (2) to the.t3-::-4shift valve (3) preventing a 2-4 shift, At the same time, thetiming accumulator (1) is charged .with fluid (2ndohst'cl'l pressure Pl). This maintains pressure in the shifttiming valve circuit for a $hort time durin~'a. 2:t3shift t.husensuring that 3rd clutch pressure is raisedsufficiently to engage 3rdgear before the 3-4': shift V"alve(3) moves. This eliminates shock during 3-4shifts. 1 - ,
2
XM0678SHIFT TIMING VALVEAND TIMING ACCUMULATOR PISTONt. Timing eecumulator piston2. Governor pressure3. 3-4 Shift v.lve
4. Shift timing valvePl 2nd Clutch Pressure
and Operation 9
-
8/3/2019 08 Auto Gearbox
10/58
AUTOMATIC GEARBOX 2.5DESCRIPTION AND OPERATION
~~;~(,,~..Kickdown ValveThis valve controls the exhaust pr.es~.,!~ref ti:1e4th c.irctt~,I.',: During 4-3 kickdown, the remaining pressure in the 4th accumulator is applied unt'ilthe. 3 ' M t . or 2nd cluteh>
-
8/3/2019 08 Auto Gearbox
11/58
AUTOMATIC GEARBOX 2.5Throttle Valve '8'This valve receives line pressure (P4t and converts it into throttle pressure '8' (P3t. Throttle pressure'S' (P3) will vary depending upon throttle opening and wiU"act upon the accumulators .
4XMOS7S
THROTTLE VAL VE '8'Pl Throttle Pressure AP2 Modulator PressureP3 Throttle Pressure BP4 Line Pressure
1. Throttle valve A2. Modulator valve3. Throttle valve B4. Filter
Modulator ValveThis valve modulates line pressure which is directed and used by throttle valve 'A' and the lock-up controlsolenoid valve.Throttle Valve 'A'This valve receives modulator pressure and converts it into throttle pressure 'A'. This pressure will varydependant on throttle opening and is used on the shift valves to provide automatic gear changes.ANote The adjustment of throttle valve 'A' is pre-set during manufacture and must not be altered.1st AccumulatorThis is connected in the 1st clutch hydraulic circuit and comprises a piston and spring. When 15t clutch isapplied, the piston in the accumulator moves damping the 1st clutch application.2nd, 3rd and 4th AccumulatorsThese operate in a similar manner to the 1st accumulator except that throttle pressure'S' (Pl) acts on thespring side of the piston. The damping effect of the accumulator changes depending upon throttle opening .
Description and eration 11
-
8/3/2019 08 Auto Gearbox
12/58
Servo ValveThis operates the reverse selector fork whic'h!i"loves a.'couplingsleev, engaging the teeth on reverse hub withthe teeth on the reverse countershaft gear. . . ..'. .ANote Servo body and servo valves are mat~Aed sets and come 'in three sizes A . 8 and C. It a servo valve is changed. one must be fitted with the same letters. .r,
AUTOMATIC GEARBOX 2.5DeSCRIPTION AND OPERAnON
1 2
..1.:, . ;to
2nd, 3rd AND 4th A c c u M i l i i lJ l J l.' " .~~~ : ,.. ,~~". ; ; :" } ~ ~ ~ t , , 3. Clutch pressureP1 Throttl8i.,pressure B1. Accumulator piston2. Accumulator springGovernorThe governor is driven by a' gear which meshes with the final drive gear.-Wlthin the governor body is agovernor valve which incorporates primary and secondary spring load9d,vJ~igtits. Operation Line pressureenters the governor via a passage around the outside of the drive spinelle."When the vehicle is stationary,the governor valve is at rest and no governor pressure enters the governor lines. As vehicle speedincreases. the governor weights move outwards and allow more line pressure to pass through the valve via apipe, inside the drive spindle into the governor lines. Governor pressul'e is then proportional to vehiclespeed. . '
4
S E R VO V A LV E1. Se~o valve2. 4th ~Iutch feed3. Reverse control valve
4. Servo valve feedP1 Governor pressureP2 Line pressure
12 Description and Operation
-
8/3/2019 08 Auto Gearbox
13/58
AUTOMATIC GEARBOX 2.5II .
, . . . P52 r-I~~
~l I. L [ : : ; ; - I \.J: , - - . . . . . .C l Ir ........~ (r o 1IT
-
TORQUE CONVERTER LOCK-UP CONTROL VALVES XM07021. Lock-up solenoid2. Lock-up cut valve3. Lock-up timing valve A4. Check valve5. Lock-up timing valve B6. Lock-up shift valve
7. Lock-up control valveP1 Modulator pressureP2 Throttle pressure AP3 Governor pressureP4 Converter pressureP5 Line pressure
'on and Operation
-
8/3/2019 08 Auto Gearbox
14/58
AurOM ATIC GEARBOX 2.5, DESCRIPTION AND OPERATION
Reverse Control ValveThis valve controls the engagement of reverse gear depending on line pressure and governor pressure.Torque Converter Lock-up Control ValvasThese consist of several valves which control timing of the lock-up piston preventing the lock-up pistonfrom vibrating in the lock-up condition.Lock-up Cut ValveThe lock-up cut valve (2) switches the line pressure port to the lock-up:timing valve 'A' (3). Whenmodulator pressure (P1) is applied to the lock-up cut valve, the ,por.t;.t~ the lock-up clutch is closed. Whenthe lock-up control solenoid (1) isener'gised, modulator pressure:exhausts and line pressure to the lock-upcut valve is transmitted to the 'lock-up timing valve A (3). __ ~.-. . ~ ,~Note The lock-up control solenoid is activated by the P G M - 1 = I : e c i J d,ependant upon signals from the vehiclespeed sensor, ooolant sen,sor and throttle angle sensor.Lock-up Timing Valve 'A' , ,_The lock-up timing valve 'A' (3) switches line pressure (PS) frbin;tl:lj,'lock-up cut valve (2 ) to the lock-upshift valve (6). When governor pressure ' (P3) overcomes sprh'lg'f",r:essure, the valve opens allowing linepressure to the lock-up shift valv'{.F ,,!>,, ' ~( >Fourth clutch pressure is applied to'tfle, timing valve whie ':asststs the spring tension during fourth speed
.. L \,.+'.' ...range, so delaying converter 10ck":uR+, , ': ,. ',,',,' " ' :; ,. :}. . .. .. ,
Lock Sho tt V I ' ,.: ,'" ..~,.o~,,'.-up I ave',:,,': , ":':~',,_,,When lock-up oonditions are fJlJQ14~-~ii.,.t'i_$UI~~~Ve~ the valve. This causes converter pressure to bedirected to the other side of the;,;:ve11,rlocR.,Op.;"p';aton.and lock-up is engaged.. ~...~a 'j.l::" " ' _ i,~ : ', " , , ' . .,,, '- '; ""Lock-up Control Valve ,,_,,', _;:.:[." . ',.'This valva controls the exhaust' pa~~" f r o . m 't1Ie:f~lease side of lock-up piston during lock-up dependingupon throttle pressure'S',Lock-up Timing Valve '8'The final lock-up timing is controlled b'Vthis valve (5) depending upon governor pressure (P3) and throttlepressure 'A' (PS) . When the lock-up shift valve (S ) is in the lock-up position, converter pressure (P4) , isdirected to this valve. When the valve is closed, converter pressure is directed to the lock-up controlvalve (7) and lock-up exhaust oil is controlled. On the other hand, when governor pressure moves the valve,the pressure feed is closed and complete lock-up is achieved.Check Valve"This valve controls converter pressure when lock-up)~,achievecl'. ,r
DIFFERENTIALThe differential is located in the gear9ase:;"d '~hares :tl:l,e..sa~e ,lubricating fluid as the gearbox, Drive tothe differential is from a gear on t'h,~'''eotll..ersbaft., The ring~ear drives the gearbox oil pump whilst a ringgear mounted on the differen,ti'al ear.rier ~ifriyefthe speedometer pinion - see 'Description: The drive shaftsare splined directly into the differenti'al.pinions.
14 Description and Operation
-
8/3/2019 08 Auto Gearbox
15/58
. .
AUTOMATIC GEARBOX 2.5
(
Between MIN and MAX marksA CAUTION Do not overfill
,~,
,Spedal ,Instructions':J
~ "vehicle 2 mile, 3i
-
8/3/2019 08 Auto Gearbox
16/58
ActionMoveRemove:PositionMarkAlignSecureCheckApplyStartSlowly moveStop whenNoteSlowly moveStop whenNoteStopAdjust
2 Adjustments
AUTOMATIC GEARBOX 2.5ADJUSTMENTS
selector lever - N [neutral]screw - selector handlehandh!t - selector lever1. checking gauge - graphic plate2. selector lever centre line3. gauge centre line - lever mark:gauge -'graphic plat ..,centre line - mark: .'\-' . , . ,i"hand and f09t brakes;engine .. " "
4. selector lever,';'" R'~initial hydraufi,: enga'g'emen~ occursposition of ! ] 1 8 1 t c :S. selectof'.l~ver - 04initial hydraOlic engagement occursposition of markengineselector cable
"::4;0 -;~ .~.: , < , .. . . ;HYDRAUUC ENGAGEMEN7X: ': C.HECK' f ji :iNSoLE FITTED
,,f .~~ '. '_ _ .~ ':,f. c
This procedure can be carried, outt~~teripi"~, whether adjustment to cable is required. It MUSTbe carried out atter adjustrnentjtQto..n.~,(l.sO.:piJ.~t~t,j;'ntting I S accurate and selector quadrant iscorrectly aligned. J~.S~~!!-( ,'. ,.'
,~.: ..~ ,l '~
180 1655
Ref . Detail'.
XM0745
Special Instructions
B 18G1555Use:adhesive tape
~
If initial engagement R or 04 outside lines
-
8/3/2019 08 Auto Gearbox
17/58
AUTOMATIC GEARBOX 2.5
~~~~ : < 5SELECTOR CABLE _ 'M J r J I I S , ..~ActionRemoveSlackenChecltMovePushTightenMoveSlackenTtghtenMoveRe-checkCarry out
Ref. Deta i l Special Instructions1.
centre consolenutcable metal sleeveselector lever - 2metal sleeve forward
See 'Body'Us:e 24 mm, 15/16 in crowsfoot spanner' : wlI i slide through olive
'~~Hold 'f'~ly.' To limit of travel, m 18 Nm, Use 24 mm, 15/16 in crowsfoot spanner2-3.4. nut .c..~ I
selector lever - Nnutnutselectorselector cablehydraulic engagement checkconsole removed
,'.Gear~ox $elector valve centralized in detentm 1B Nnl, Use 24 mm, 15/16 in crowsfoot spannerTo engage all positions on quadrant
justrnents
-
8/3/2019 08 Auto Gearbox
18/58
Action Ref. Detail Special Instructions'-.J--
Move selector lever - NCentre punch A. selector lever centre lineMarie: 8. quadrant - rearward .~ Ato B 8.5 mm. 0.335 in
C. quadrant - forward A to C 7.5 rnrn, 0.295 inStart engine, Apply foot and parking brakesSlowly move 1 . selector lever - RStop when initial hydraulic engagement occursCheck centre punch - quadrant mark Within 0.5 mrn, 0.020 inSlowly move 2. selector lever - 04Stop when initial hydraulic engagement occursCheck centre punch - quadrant mark Within 0.5 mm. 0.020 in
If not OK. re-adjust cableReassemble componentsRe-check setting gaugeCany out hydraulic engagement check
console fitted
.AUTOMATIC GEARBOX 2.5ADJUSTMENTS
XM051~
HYD RAULIC ENG AG EM ENT'- CHECK CONSOLE REMOVED'This procedure MUST be carried out after selector cable has been adjusted.
4 Adjustments
-
8/3/2019 08 Auto Gearbox
19/58
AUTOMATIC GEARBOX 2.5
XM0 6 6 7'+~ ;'.
KlCKDOWN CABLE - >CH~4 i f .?~f lST..' /j,,~~~,':~.~{r'.: r ~ " . :. .Action Raf. Detail ' , > " , ~ ': 'c
RemoveSlacken
PressScrewTightenCheck:
MoveStartDepressCheckReassemble
2. gearbox lever3. upper locknut - abutment bracket4. lower locknut - abutment bracket5. cable free play
air cleaner1. locknuts - cable
Spacial.InstructionsSee 'Fuel 2.5'2 off'Ii,CAUTION Top locknut must be slackened to. e"d., thread of bracket, D own fully
cable moves freelygearbox lever movement
Gearbox lever must move as soon asthrottle lever is operatedWhen accelerator is fully pressedShould be 2 to 4 mm, 0.08 to 0.16 in furthermovement when accelerator pedal is touchingthe floor
. selector lever -Pengineaccelerator pedalgearbox levercomponents
GraduallyMovement is synchronised with throttle lever
Adjustments
-
8/3/2019 08 Auto Gearbox
20/58
'~.~ ~.:~. "
' l " .
'.'
~ . ' .
-
8/3/2019 08 Auto Gearbox
21/58
Action Ref. Detail Slacken 1. locknut - cableRelease 2. cable - bracket and throttle leverSlacken 3 . locknut - cableRelease 4 . nipple - throttle leverWithdraw 5. cableReassemble componentsAdjust cable
AUTOMATIC GEARBOX 2.5REP
KICKDOWN CABLE - RENEWSpecial Instructions
See 'Adjustments'
Repairs
-
8/3/2019 08 Auto Gearbox
22/58
.AUTOMATIC GEARBOX 2.5' . REPA IRS
S T A R T E R IN H IB IT O R / R E V E R S E LIG H T S W IT C H - F /E N E WAction Detail Special Instructionsef.PositionDisconnectRaiseReleaseRemove:
vehicle on rampearth lead - batteryrampbulb holders - selector housing '.'selector housil'lg" .
1. E clip - cable ,.~2. cable - lever '.'3. nut - cable
nuts - front exhaust pipepipe - manifoldsflange packingsmounting rubbersexhaust assemblypop rivets - lever housing4. bolts - lever housing
5. multiplugs8. lever housing7. detent bracket - housinga bolt - lever9. bolt - switch10. switchcomponents
starter operates in P and N only
2 screws
ReleaseSlacken: 24 mm, 15/16 in crowsfoot spannerS' offReleaseRemoveReleaselower
Drill outRemoveDisconnectRemove:
2 off2 offHeater ductS off2 off
ReassembleCheck
2 Repairs
-
8/3/2019 08 Auto Gearbox
23/58
Action Ref. DetailRaise: vehicle
bonnetDisconnect earth lead - battery Release bulb holder - selector housingRemove: selector housing1. E clip - selector cable tRelease 2. cable - ' evel 'Slacken 3 . nut -, housingRemove: 4. bolt -cable covers. cable cover - gearbox
longitudinal support - vehicle8 . split pin - selector cable
Withdraw 7 . clevis pinRelease 8. cable - gearbox leverRemove: heat shield
selector cableFit selector cable - converter housingLocate selector cable in leverPosition outer cable retainerReassemble componentsAdjust selector cable
AUTOMATIC GEARBOX 2.5
S E LE C TO R C AB LE - R E N E W'S~etnaiInstructions' . . . .. .On ramp'
,.. .
Use 24 mm, '15/16 in crowsfoot spanner
See 'Engine 2.5' for tightening sequence oflongitudinal supportSee 'Adjustments'
-
8/3/2019 08 Auto Gearbox
24/58
AUTOMATIC GEARBOX 2.5REPAIRS
1 8 " f
GEARBOX AND TORQUE CONVERTER - RENEWAction Ref. Detail Special InstructionsRaiseDisconnectRemovePositionSlackenReleaseRemoveRelease
bonnetearth lead - batterystarter motordrain trayclip - oil cooler hosehose - pipebolt - harness bracketharness
See 'ElectricafUnder gearbox
4 Repairs
-
8/3/2019 08 Auto Gearbox
25/58
RemoveReleasePlugDrainSlackenRelease:MoveRemoveReleaseRemove:ReleaseRemoveReleaseRemove: Release, SupportMoveRemove:
MoveRemove:
AUTOMATIC GEARBOX 2.5
MartRemove:
WithdrawReleaseMoveSupportRemove:MoveRemove:ReteaseRemove:ReleaseRefitRemoveMovePositionTightenFitSupportRelease LowerRelease
1. clips _ oil cooler hose 2 off m 3.3 NmAi CAUTION Ensure hoses are up.}" .3rd rtb, clipbetween 2nd and 3rd rib with s(;rew to outside
2. hoseshose and pipe connectionsfluid _ ge'arbo,x3. locknut - Idekd"own cable4. threiad~ bar - bracketS. nipple - lever6. kiekdow,n cable
nut - top link balrjointball jointsplit pin - ball jointnut _' ball jointtraCK rodnut - bottom swivel jointswivel jointbolt - forkbolt _ forkforkdrive shafts - gearboxsuspension leg ':",drive shaft.(su$pension legtie' ,rQd .. ... 4,_ : .. ._ ,', "scre~~;;: ~r~ P ! ; > 8 ' ,to ABSwirint", ~Cker" ;,~brat'e "tlO'$.e"an ,jbolts ~::-ctt)ss.mbcil;tS''':''snubber 'b~( ,bolt - drive plat.e 'fzsnubber bracket and or/ver ;, ,;;.'"drive plate _ torqUe';:6nve~'~,'/' For reassemblybolts - drive plate:' ' = . ._ ,' , L," 8'offJ~ 12 Nm. Rotate engine to gain accessbolt _ selector cable' cover' ">split pin - clevis pin I ! ! I Secures selector cableclevis pincable - gearboxcable
Fit plug on completion2 off'(~sfde! l f i J c4 a NmI,Js~~:D'1 8G ; 063A"Ii) ,4~_Nm
Use 0 18G 1063AlillOO NmUse~'D 18G 2To' lower arm m 65 NmTo shock absorber m 44 Nm
",
See 'Drive Shafts 2.5'Use hydraulic jackAsideSee 'Suspension'
7 .3 offAside8 off3 'cff
9.10.11.
engine12. bolts - front centre mounting
bolts - rear mounting13. bolt - behind R.H. driveshaft14. bolt - torque rod15. bolts _ tcrque rod bracket, 6. bracket17. bolts18. bolt _ speedometer pinion assembly19. speedometer pinion assembly20. 0 ring _ pinion '
bolt _ earth leadearth lead _ gearbox lifting eyeboltbolt _ harness strapharnesslifting eye
AsideUse trolley jackTo gearbox 2 off m 39 NmTo gearbox 2 off m 39 Nmm 22 NmIi) 40 NmCollect special nut2 off m 40 Nm eAside3 off below throttle bodym 15 NmeIi) 40 Nmm 40 NmAsideUpper eye of torque rod bracket mountingbolt hole
bolt _ lifting eyechainsgearbox on chainsgearboxR.H. drive shaft extensiongearboxchains - gearbox
Manoeuvre gearbox from below vehiele
Continued ....Repairs 5
-
8/3/2019 08 Auto Gearbox
26/58
AUTOMATIC GEARBOX 2.5REPAIRS
< .
XM0 6 6 2
ReleaseRemove: 21.22.23., i > s . ' " . ; 'torque conv..l#itr~: hous;Qgo ring - .torQ~ converterseal - hQUli,ng .
components When fittinlt drive plate to converter,rotate crankshaft to gain access to bolts.Initially t~'half torque then to fulltorque in dtagonal sequenceSe. ~Adjustments'See
-
8/3/2019 08 Auto Gearbox
27/58
XM069SAE N D C O V E R - R E N E WAction Ref. Detail Special InstructionsRemove: torque converter1. end cover bolts 10 off E D 12 Nm
2- cover3. gasket and 0 rings e4. plugs - end cover 4 off E D 18 Nm5. sealing washers 4 off e
Collect 6- ball and springRemove: 7. circlip - low accumulator
8. accumulator cover9 . springs 2 off10. piston11. o rings 2 off e12- circlips - 1stl3rd clutch accumulator 2 off13. 1st/3rd clutch pipes
Move 14. flanges - down pipes Remove,: 15. pins and washer flanges - pipes16. o rings - flanges 3 off eReassemble: components Lubricate all components with cleantransmission fluid: smear gasket withpetroleum elly
epairs
AUTOMATIC GEARBOX 2.5
15(i5
.~~~14 ~/11.-_--12 .
~ , . : . . " , 87
-
8/3/2019 08 Auto Gearbox
28/58
AUTOMATIC GEARBOX 2.5
epairs
-
8/3/2019 08 Auto Gearbox
29/58
CollectRemove:
EngageRemove:
DisengageRemove:RemovePositionRemove:
Release:Remove:
CollectReleaseRemoveCollectRemove:
WithdrawRemove:
-s -
AUTOMATIC GEARBOX 2.5
Ref. Detail Sp~cial Instructionsend eover1. holding tool - mainshaftstaking _ , st elutch nut2. nut _ main""aft3. 15t clutch - mainshaft
4. 1st gear - main5hafts. . bearing$ and thrust washers6.- bearing sleeve - mainshaft7. thrust washer - mainshaft8. 0 rings - mainshaft9. parking pawlstaking - countershaft nut10. nut - countershaft11. parking pawl12. parking gear - countershaft1st gear -'countershaft13. one way clutch - countershaftgearbox14. stop pin1s.. parklng,,!wl18. 5prina .17. shaft18. lock tab _ boffbolt .19. bolt and tabwastter ","20.21.22.23.24.2& .26.27.28.29.30.
stopper - armspringsplit pinroller pin and washerroller and parking brake leverslock tabbolt _ throttle levertabwasherthrottle lever at:'ldspringwash,rbolts _ dipstick tubedipstick tube-,o ring ~.(bolts -tr~s'miP:iif!" 0 ,n9
, . ' ; \" . ' , . '
n 18G 1530&195 Nm fJ"'~ :
& I 95 Nm. nut has a left hand thread.fJ
On eonverter housing facePark lock mechanism
~ , L:. .... II15 Nm fJ tabwasher
6 J 12 Nmem 12 Nme15 off & I 45 NmRemovebolts in order shown
XM0663
Continued ....
-
8/3/2019 08 Auto Gearbox
30/58
AUTOMATICREPAIRS GEARBOX 2.5
36
10 Repairs
-
8/3/2019 08 Auto Gearbox
31/58
AUTOMATIC GEARBOX 2.5Remove: 38.
39.WrthdrawCollect 40.Remove: 41.42. 43-44.InspectLubricateCheckReassembleTighten
~:"Vse 8 suitable drift to remove bearings.bolts - holder ..., "... ,.' 2 .off Ii) 12 Nmholder and reverse idl~r sh,1t. - . ; # < ~ \ . ; f . . . , . . .ball and spring '. . ~'>l.$'1'bolt : m 12 Nm
Remove: 31. transmission casing32. gasket
throttle shaft oil seals33. dowels34. reverse idler gear35. bearing
reverse selector fork36. differential bearing outer track37. shims
snap rings - bearingsmainshaft and countershaftbearings - transmission casing
'~bearings and oil seal
ea3 off
CollectRemove:
washerspringshaft
"it:> , : , ' ~ , ~ ,.~,~~~~, .;' I ! ! J
; , . _For wear and damage and renew as necessaryUse transmission fluidIf differential assembly bearings ortransmission easing have been renewed- see 'Differential assembly'Use e laG 1525 when fitting oil sealIn sequence illustrated
XMOS65
Repairs 11
-
8/3/2019 08 Auto Gearbox
32/58
~. AUTOMATIC GEARBOX 2.5_REPARS
ff'~ 151213/ @14
XM0681
MAINSHAFT - RENEWActionRemove:
CleanLubricateInspectCleanLubricate
12 Repairs
Ref. Special In.Jructions, 'r~ '_."~Detail
1.
end covertransmission casingcountershaftmainshaftsnap ring ,I . . ;4 :t h 9 !, ar bearing . ~ L. ~-' ~ ~..,thrust wa~her, beari'1l,'wfl 4t~:1J.t8rneedle b'8'arings.4th geal' coUAl',thrust 'ne,e~le bearing' and thrlJist )Masher2nd / 4th clutch
2.3.4 .5.6.7.8.9.10.1 1 .12.13.14.15.
2 off erings '. ','2nd gear thrust washer2nd gear thrust bearing2nd gear 'needle bearingthrust needle bearingo ringssnap ringneedle bearingspacer collarmetal sealing ringscomponents
3 off e3 off eUse transmisstcn fluid or chlorinated solventDry components immediatelyUse tran-smi.ssion fluidFor wear, ,renew components as necessaryIn mainsh:e'ftUse transmission fluidANote Thrust needle bearings with open recesswithin the needle cage must be fitted with recessfacing thrust washer
bearingscomponentslubrication holeso rings and metal sealing rings
-
8/3/2019 08 Auto Gearbox
33/58
r" ~;..
F'rt: 16. metal sealing rings 3 off17. o rings 3 off18. spacer collar19. needle bearing
20. snap ring21. 2nd gear thrust bearing22- needle bearing23. 2nd gear24. o rings 2 off25. 2nd / 4th clutch thrust bearingF'IX 26. 2nd / 4th clutch thrust washer Use petroleum jelly
- clutchLocate 27. 2nd / 4th clutch to mainshaft Engage all clutch platesCheck clutch flange Must be level with top of splinesF'rt: 28. 4th gear thrust washer
29. 4th gear thrust bearing30. 4th gear collar31. needle bearings :2 off32. 4th gear Ensure gear engages with all clutch plates33. thrust bearing34. thrust washer Dished face towards snap ring35. snap rings 2 offLocate 36. mainshaft bearing On mainshaft
F'rt: 37. 1st gear collar Flange of collar towards mainshaft bearing38. , st gear thrust washer39. needle bearing 40. , st gear41. thrust bearing42. thrust washer43. , st clutch Continued ....44. nut
AUTOMATIC GEARBOX 2.5
~20~~19 , , ~ 18~ .. 1~~6
,.~~
~~ - '''-J 45
-
8/3/2019 08 Auto Gearbox
34/58
RemoveFitReassembleFit
AUTOMATIC GEARBOX 2.5mainshattnut
45. clearanceiJ lSG 1530~ 35 NmBetween shoulder of 2nd gear and 3rd gearn Should be 0.07 to 0.15 mmIf clearance is incorrect, proceedOt 2nd/4th clutch thrust washerWhich will give correct clearancen Thrust washers available4.00. .mm, 4.05 mm4.1Ol'hm; 4.15 mm4.2.0 ,mm, 4.25 mm4.3Q.mm, 4.35 mm4.40 mm,Retat". nut for retitting-- ,j~~> . . : ~ : . ~ ~ . :'~~.';;'; mainshaft nut to m 95 Nm'It s . ' N ' r i 'I . nut has a left hand thread;:.~:~~\~' ~ : ~ ~ '
48. thickness
thrust washer
items 36 - 44selected thrust washertransmission casingcomponentsnew countershaft nut
e ,
r-.L
COUNTERSHAFT - RENEwXM0680
ActionRemove:
SlideRemove:
Ref. Special Instructionsetailtransmission casingselector forkmainshaftcountershaft1. 4th gear - countershaft
2. needle bearing3. spacer collar4. 2nd gear5. 2nd gear thrust bearing8. split collar7. 3rd gear8. needle bearing9. 3rd gear thrust bearing10. splined thrust washer11. 3rd clutch12. 0 rings
2 otf segments
2 off e
-
8/3/2019 08 Auto Gearbox
35/58
AUTOMATIC GEARBOX 2.5
Clean componentsLubricate bearingsInspect componentsClean lubrication holesLubricate o ringsFit 13. o rings
14. 3rd clutch15. thrust washer16. thrust bearing17. needle bearing1& 3rd gear Engage clutch plates
25
..J
38,39
32 XM0691Use transmission fluid or chlorinated solventDry components immediatelyUse transmission fluidFor wear, renew as necessaryIn countershaftUse transmission fluid2 off
Fully
Continued ....
-
8/3/2019 08 Auto Gearbox
36/58
PositionFitTightenMeasure:
Select
RemoveFrtMeasureLeaveSlideMeasureSlideMeasureCompareMeasureSelect
RemoveFitReassembleFit:CompleteReassemble
16 Repairs
AUTOMATIC GEARBOX 2.5REPAJRS19. split collars20. thrust bearing21. 2nd gear22. spacer collar23. 4th gear24. needlebearing25. reverse gear selector
hub and reverse gear26. needle bearing27. collar28. countershaft bearing and snap ring29. collar30. needle bearing31. 1st gear32. one way clutch33. parking gear
countershaft in vice34. new countershaft nut
nut35. clearance
. .36. 4th gear spacer collarcollar
original collarselected collar
37. clearancefeeler gauge3rd gear38. clearance-3rd gear
39. clearancetwo readings
40. splined thrust washerthrust washer
nutthrust washercomponentsmainshafttransmission casingassembly of countershattcomponents
--\, ')~.:; .~t
Groove faces'towards reverse gear~.. : .
U s e , soft jawed vice'l&~Qta)Nut has lett-hand threads' ., ,:~,35)~"m' ,~.$.~~!e'1 ,reverse gear selector hub and':.s1lP\l!Jder~,9n,th gear.
.: rI'shoQJd~be 0.07 to 0.15 mm'S""'. If i! ,:e9rr,pt . proceedLengt ! t :~hicn gi~s correct clearance. .; -. ". t :QUaC engths available'47~SO~, 47.55 mm47.601"11'"":4.7.65mm47.70mm.47.75 mm47:aOmm ,,' .'"
\ .
Between reverse selector hub and 4th gearIn positionTowards 2nd gearB.!Stween 2nd and 3rd gearsAw.ay from 2nd geara'tween 2nl.and 3rd gears. Difference $hould be 0.07 to 0.15 mmIt incgr':a~ proceedThickness.' .
~';s'i.,Which 91~~correct clearance',.' rI Thrust washers available\, 4.50 mm, 4.55 mm
4.60 mm, 4.65 mm" 4.70 mm, 4.75 mm4.80 min, 4.85 mm4.90 mmRetain nut for refittingSelected thicknessAs far as 4th gear
Tighten nut to l i J 95 Nm
-
8/3/2019 08 Auto Gearbox
37/58
AUTOMATIC GEARBOX 2.5
LOCK - UP CONTROL SOLENOID / TERMINAt BLOCK - RENEWActionRemove:
BendRemove:ReleaseRemove:
Re8'ssemble
Ref. Detailend cover ,._transmission ~jfn,g;
1. nuts - termibol$> ".:;:;..'" ",', ,lead , , ,', ,2. bolt - lock - up con~olsol'enoi'd3. solenoid ' " ,4. extension leads - terminal block5. screws - terminal block6. terminal block and plate7. screws - extension lead plate
components
, '2 off ::.... ,T89S;':;u~l.~e clear of leads
2 off
Repairs 17
-
8/3/2019 08 Auto Gearbox
38/58
E A R B O X \ : 2 . ~ 5 = = = = = = 1UTOMATIC G _~p~~~~--------
180 1016
XM0693
Repairs
-
8/3/2019 08 Auto Gearbox
39/58
AUTOMATIC GEARBOX 2.5-RENEW
Special Instructionsef. Detailend covertransmission casingmainshaftcountershaftclutch1. snap ring2- end plate, discs and clutch plates
Position 3. clutch - thread of toolCompress clutch springRemove 4. snap ringSlacken toolCollect 5 . spring retainer
6. springRemove: 7 clutch piston
8. o ringsCheck components for wear and damage
The following instructions are applicable to all clutches in the gearbo)(
As necessaryf,:
o lSG 1016o 1SG 1016Use compressed aireRenew components as necessaryANote Clutch plates and discs ~hould only berenewed in complete setso rings. 'clutch plates. discs Use transmission fluid
and pistono rings .piston - clutcb " ~,;," ,spring r~.tifner and jqaP,ring to .c;1~~chspring ";,,:' " " ; , t ' : " , :i.-.:' g'lSG1016, . ' e . .. . . ~ ~j' _.I" ;~snap ring v ~~ . ~ .: ',"tool "."~'~:\"/;I: ' i '1~G 1016discs, plates and end plate' . "~ '! 'l \snap ring
9. feeler gauges
new end plate
clutch operationcomponents
~... ~.: ; . r . BetWeen top clutch plate and end platerJ Measure clearance:t st clutch - 0.65 to 0.85 mm2nd clutch - 0.50 to 0.70 mm3rd clutch - 0.50 to 0.70 mm4th clutch - 0.40 to 0.60 mmIf clearance is not correctEnd plate thickness available:-No. 1 - 2.1 mm No.2 - 2.2 mmNo.3 - 2.3 mm No.4 - 2.4 mmNo. 5 - 2.5 mm No.6 - 2.6 mmNo.7 - 2.7 mm No.8 - 2.8 mmNo.9 - 2.9 mm No. 10 - 3.0 mmApply compressed air to ports arrowed inillustration
LubricateFitPositionCompressFitRemoveFitInsert
CheckReassemble
Repairs 19
-
8/3/2019 08 Auto Gearbox
40/58
GOVERNOR - RENEWAction Raf. OatailRemove: end cover
transmission casingmainshaftcountershaft
Release: locking tabs - governorbolts - valve
Remove: 1. bolts - governor2- tabwashersgovernor
Release locking tabs - boltsRemove: 3 . bolts4- tabwashers
governor assembly5. plate
20 Repairs
:C:j(~,,~
.AUTOMATIC GEARBOX 2.5REPAJRS
, f XM0687
Spacial Instructions
3 off m 12 Nme2 off m 12 Nmf'I
~9
-
8/3/2019 08 Auto Gearbox
41/58
Action Ref. DetailRemove: end cover
transmission casingmainshaftcountershaftlock - up control solenoid
1. bolts - lock - up valve body2. valve body and separator plate3. dowels4. pin - reverse control valve cap5. valve and spring6. pin - lock - up shift valve cap7 . lock - up shift valve and springClaa" components Examine componentsLubricate componentsReassemble components
2LOCK - UP VALVE BODY ASSEMBLY - RENEW
CleanCheck:
CheckReassemble
AUTOMATIC GEARBOX 2.5S. filter7. dowels8. pipe9. circlip - drive gear10. gear11. woodruff key12. shaft13. washers14. governor valve15. circlip - weights and spring16. circlip - weights17. weigbt 'and spring assembly
comR9nentscdmi:\QI'l8f1ts for wears"'a ff'! '~" ., '.body:,." , ,Weigh.,.S I B '" ' , ; .:c O ~ F n ; ~ ';r.".~~.' '~','~-.';.'. "'\ 4 -
Clean filter in paraffin2 off
2 off
Use transmission fluid or chlorinated solventRenew as necessaryMust be free to turn in governor bodyFor wearMust be free to move when assembled to shaft
L _
2 XM0670
Special Instructions
5 off Ii! '2 Nm2 off
Use transmission fluidFor wear, renew if necessaryUse transmission fluid
Repairs 21
-
8/3/2019 08 Auto Gearbox
42/58
REGULATOR VALVE BODY ASSEMBLY - RENEWAction Ref. Detail Special InstructionsRemove: end cover
transmission casingmainshaftcountershaftclutchgovernorlock - up control solenoidand terminal block.lock - up valve body assembly1. bolt - regulator valve body fB12Nm2- regulator valve body
3. stop pin - stator shaft4 . stator shaft5. o ring e8. pin - valve cap lock - up timing1 . cap, lock - up timing valve and spring8. pin - valve cap lock - up control9. cap, lock - up control valve and spring10. bolt - regulator valve spring cap fiJl0Nm11. cap, seat, springs and regulator valve
Cleen components Use transmission fluidCheck components For wear, renew as necessaryLUbricate components Use transmission fluidReuse",ble components
22 Repairs
2
AUTOMATIC GEARBOX 2.5REPAJRS
~ '~- ~'~M:""
3 i.'i'"t~.,,.', ,
'tt'\: ., ;" .
XM0686
-
8/3/2019 08 Auto Gearbox
43/58
AUTOMATIC GEARBOX 2.5
m14Nmfl
.: . .R E V E R S E S E LE C TO R FO R K - R E N E W
Special Instructions Action Ref. DetailRemove: gearbox housingthrottle shaft oil sealdowels
1 . reverse gear - countershaft2. bearing and sleeveRetease: 3. locking tab - selector fork bolt4. bolt - selector fork
tab washerS. fork, selector and selector hubReassemble components
fl3 off
-
8/3/2019 08 Auto Gearbox
44/58
AUTOMATIC GEARBOX 2.5
13
. XM0698
airs
-
8/3/2019 08 Auto Gearbox
45/58
AUTOMATIC GEARBOX 2.5 SERVO VALVE BODY ASSEMBLY - RENEWAction Ref. Detail Special InstructionsFtemove: end cover
transmission casingmainshaftcpU'ntershaftclutch. ).governor 0lock - ulf control solenoidand terminal ~Ioc.klock - up valve body assemblyregulator lIal'(8 body assembly1. oil feed pipes' - servo assemblyoil baffle pl.ate.
2. bolts - 2nd / 3rd accumulatorSprit.lg eever3. accumulator spring cover
4. 2nd / lr:d accumulator springs5. bolts ~~,accumulator cover6. aceun,ufa10r cover7. Q.,ring8. sp,ring holder9. sp(injJ, .10. EeJip:':" throttle shaft11. bolts;,:-"se;;~ body
caPi::,:"" ,~" : ~t(C8 c.ontrol val~e12. . throttle'tfl f t~ , . - \S! ,&4body assembly13. separator ~18te,:;;i':"'. ". .ball and spring' '.' . ,~~,.
14. pistons . < : i . ! 15. 0 rings - pistonsshift fork shafto ring - shaft
16. servo valve17. servo return spring18. 0 ring19. plate - servo orifice
control valve20. spring and servo orificecontrol valve21. bolt - modulatorbody assembly'
22. modulator body and seperator plate23. magnet - servo bodyball and spring - main valve body
componentscomponentscomponentscomponents
2 off m 12 Nm2 off2 off2 off m 12 NmRenew clip if distorted6 off m 12 Nm
CollectRemove:CollectRemove:
:; m 12 NmCollectClaanExamineLubricateReassemble:
Use transmission fluidFor wear, renew as necessaryUse transmission fluidCAUTION Compress accumulator springs whentightening the accumulator cover boltsor stripping of bolt threads will occur
Repairs
-
8/3/2019 08 Auto Gearbox
46/58
1
XM0694
-
8/3/2019 08 Auto Gearbox
47/58
AUTOMATIC GEARBOX 2.5
Special Instructionsef. DetailSECONDARY VALVE BODY ASSEMBLY - RENEW
end covertransmission casingmainshaft "countershaftclutch.governorlock - up control solenoidand terminal blocklock - up valve body assembIY.;l',1'regulator valve body assem~fJ;f!J~;servo valve body asseml;ly ...."'.'secondary valve body- main valve body timing accumulators,iri/lg and valveball .. '"separator platedowels . ,. ',;\.pins - vatyes.clutch pressure control valvecomponentsreverse contrbl valve componentskickdown valve componentsspring seat
"
Separate: 1. Collect 2.3.Remove: 4.S.6.7 .8.9 .10.
11.12.13.14.
CleanExamineLubricateRea.semble
ActionRemove:
,-. J : ; / ' .~. . . .~. '.2 of"" ,3 off
3 off, accumul.ator control valve spring.lock-up cut )lalve spring,shift.timi"" valve spring
accumulator control valve compone,ntsshift timing valve components' '" -rlock - up cut valve eomponents ,":!; ..... ~~.filter ,'. _. "''l'',R' .components'''_':'' "'U~e~rans"';ission fluidcomponents" ": .,,::For wear, renew as necessarycomponents " Use tr8l1smis'sion fluidcomponents
P'
-
8/3/2019 08 Auto Gearbox
48/58
AUTOMATIC GEARBOX 2.5
~e?WMo
XM0689
;;MA IN VA LVE BODY A SSEMBLY - RENEWAction Ref. Detail Special InstructionsRemove: end cover
transmission casingmainshattcounters haftclutchgovernorlock - up control solenoidand terminal blocklock - up valve body assemblyregulator valve body assemblyservo valve body assemblysecondary valve body
1. split pin2. clevis pin3. washers and rollers4. manual valve5. bolts - main valve body
CollectPositionRemove
To give access to bolts5 off, 10mm bolts m 12 Nm
12mm bolts f D 28 Nm
-
8/3/2019 08 Auto Gearbox
49/58
'.
AUTOMATIC GEARBOX 2.5
Remove:
CollectRemove:
CollectRemoveCleanExamineLubricateReassemble
S. valve body7. converter check valve and spring8. oil pump gears and shaft9. separator plate10. steel balls
Gears are matched assembly3 off i A CAUTION Do not use a magnetto collect balls
11. cap - relief valve
12. spring and valve, 3. pin - orifice control valve cap14. cap - orifice control valve15. valve and spring
manual valve springrollers
16. manual valve17. screws - cover plates18. plates19. sleeves20. valves and springs21. balls and springs22. filtercomponents
componentscomponentscomponents
XM0690
6 off
eUse transmission fluidFor wear, renew as necessaryUSB transmission fluidCAUTION Ensure rollers locate in grooves inmanual valve and that chamfer of 0,1pumpdriven gear faces the separator plate
RepairS
-
8/3/2019 08 Auto Gearbox
50/58
f. , . s ~ ~
AUTOMATIC GEARBOX 2.5
180 21862-3
XM0700
Repairs
-
8/3/2019 08 Auto Gearbox
51/58
AUTOMATIC GEARBOX 2.5
. .Remove:
Securet. Remove: ,.SecureRemove: 2-Drift out 3.4.Remove: 5.6.7.aC.leanImmediatelyexamine
L ASSEMBL Y - RENEWRef. Detail Special Instructions
In soft jawed vicei!18G 2 and a suitable thrust buttonUse soft jawed vice'0 off iii 129 Nm LH. threade Use II soft driftUse a soft drift
Use chlorinated solventUse transmission fluidFo~.wear, renew as necessary
Continued. , ..
end covertransmission casingmainshaftcountershaftgovernorlock - up control solenoidand termi,nal block'lock " u t i valve body assemblyreQ1tlato~ valve body assembly'servo'yaive' body assemblysecon#.ary valve bodymain va'lv.e'bodyditferen,' ~ssemblydiffere sS'8mbly,differeriti.r "eatingsditf.rei\~ :.~s~bly - vicecrow, '. 6eUn,'iic.ebolts: ; 1 , ' ,.o,wn~",heeldiff.t.~:ptla'i :aj:$'.~bIY, r: ,viceroll pin ~'" ,"1{- ,pinion sh8,tt~:.::, ,pinion thrust washers f:pinion side gearsspring ring - differenti.l~1 .,speedometer drive gear'" differentialcomponentslubricate bearings ", -.',components
":,
-
8/3/2019 08 Auto Gearbox
52/58
: : A , i .U ~ T ~ O ~ M :A ~ T ~ I ~ C G :E = A ~ R - = - B _ O _ X 2 _ .5
17
XM0701
32 Repairs
18G 1396
-
8/3/2019 08 Auto Gearbox
53/58
FrtPlaceFitPositionMeasure:Adjust
AUTOMATIC GEARBOX 2.5
FrtSecureFit:
9. differential gears. pinions andthrust washers to carriergears To align pinions and thrust
washers with driliings in carrierUse a soft drift. Do notfit roll pin at this stagei!l8G 1396 J.Note Largest bearing is fittedspeedometer drive gear sideOn suitable Vee blocks
10. pin ion shaft11. differential bearings carrier12. differential assembly13. drive shafts14. D.T.I. gauge15. backlash-of both pinion gears Record figures obta inedn Correct backlash is 0.05 to 0.15 mm
By means of thrust washersn Thrust washers available0.70 mm. 0.75 mm0.80 mm. 0.85 mm0.90 mm. 0.95 mm1.00 mrn, 1.05 mmA CAUTION Thrust washers selected must beof equal thickness
backla~h
selected thrust washers16. pinion shaft17. speedomete~ drive gear18. .',snap rin9.' .
, ),-,
Use a new roll pinA CAUTION Ensure snap ring abuts againstroll pinChamfer on inner radius of gearfaces the carrier6 1 129 Nm. Bolts have LH.thread and must be tightened progressively
19. gear - earrier;
-
8/3/2019 08 Auto Gearbox
54/58
AUTOMATIC GEARBOX 2.5
180 1527
XM0661
34 Re
-
8/3/2019 08 Auto Gearbox
55/58
AUTOMATIC GEARBOX 2.521. differential assembly
22 -23.
In torque converter housing~Note If new bearings have been fitted,new outer races will need to be fittedin transmission casing and torqueconverter housing
outer bearing track - transmission caseshims - transmission caseshims 2 off, total thickness of shims must
equal 2.15 mmF " r t 24. shims and outer bearing track25. transmission casingTighten 2&. securing boltsRotate diff .rentfalF " r t 27. o 18G 1527 - shaft28. o MS 103 - 0 l8G 1527Rotate differential
Use a new gasket fitted dry, m 45 Nm.To settle 'bearingso 18G 1 527 and a socket barANote Torque required to turn differentialshould be:n Existing bearings 2.5 - 3.6 NmNew bearings 2.7 - 3.9 NmI f reading is outside limits, select alternativethickness shim.One shim thick.ness will adjust figure by 0.4 Nmn Shims availableA 0.90mmB 0 .95 mmC 1.00mmo 1.05 mmE 1.10 mmF", 1.15 mm'G lo ".20 mmH".1.26. mm~,,:. 1.30mmoJ 1.35 mmReq",lred to rotate differential
~ .1, 'O"" ' .e, /'
' .v ' . . ,. 'I:.... ~FitRecheckReassemble
selected shimstorquecomponents
-
8/3/2019 08 Auto Gearbox
56/58
.AUTOMATIC .GEARBOX 2.5
TORQUE CONVERTER HOUSING - RENEWActionRemove:
ReleaseRemove
Ref. Special Instructions
Detailend covertransmission casingmainshaftcountershaftclutchgovernorlock - up control solenoidand terminal blocklock - up valve body assemblyregulator valve body assemblyservo valve body assemblysecondary valve bodymain valve body
1. differential assembly2. bearing outer tracklocking tab - selector shaft bolts
3. bolt m12Nm
Repairs
-
8/3/2019 08 Auto Gearbox
57/58
AUTOMATIC GEARBOX 2.5
CollectRemove
4. tab washer5. connector6. shaft7. oil seal8. plugs - converter housing9. sealing washers
banjo bolt - oil' ,hosesealing washerspipe
f15 off, fi ) 18 Nm5 off. e6 J 18,Nm',.~ off. e
18G 284-12
~.-12@-1318G284-7M0664
Use D18G 284 and B l8G 284-7Use 0 l8G 284 and D l8G 284-12f1Use chlorinated solventImmediately, use transmission fluidFor wear, renew as necessary
Remove: 10. countershaft bearing11. oil barrier plate12. mainshaft bearing13. mainshaft oil seal
componentsbearingscomponentsconverter housing oilwayscomponents Ensure snap rings are correctly located
on bearings. Lubricate mainshaft oilseal with petroleum jelly
CleanLubricateExamineCleanReassemble
-
8/3/2019 08 Auto Gearbox
58/58
AUTOMATIC GEARBOX 2.5REPAIRS
, ., ' ' ( . . " , . o ! '
S E L E C T O R SUDE INDIC4 T R ~ ~ / ! g I N E W")'-i~ - ',I.i: ..:_' ,~Action R.f. Detail Sp.~i.1 Instructions'.selector leve1. screw - sele.Ctol'handl.2. selector hiVIdle - lever3 graphic 'panel - console
4. slide indicator - graphic panelcomponeots
MoveRemove To position NLever at rear edge
Reassemble Ensure tree action of indicator
XM0785