Assembling the automatic transmission

63. Press the outer rotating ring of the differential bearing into the gearbox housing (Automatic transmission F4A42, F4A51) (pic. 11.307).

Model	Special tool
F4A42	MV990935, MV990938
F4A51	MV990936, MV990938

64. Press the outer rotating race of the secondary shaft bearing into the gearbox housing.

65. Install the old insert and circlip.

66. Using special tools, install the transfer case gear (Automatic transmission F4A41 from January 1998, F4A42-1 - from January 1998, F4A42-2 with freewheel and F4A51) (pic. 11.308).




67. Tighten the transfer box gear bearing bolts and tighten them to the required torque (rice. 11.299).

68. Install 1st/Reverse detent piston, return spring and detent spring (pic. 11.309). Check the identification grooves in the inner rotating ring of the freewheel. Install the freewheel inner rotating ring with O-ring into the transfer case pinion bearing with the grooves along line A-A (Automatic transmission F4A42-2 with freewheel and F4A51).



69. Install the circlip (rice. 11.298).

70. Install the shaft spring (rice. 11.295).

71. Install brake discs, friction plates, indicator and circlip (pic. 11.310 a,b).

Attention! At this point, the pressure plate cannot yet be installed.

Pic. 11.310a. Install brake discs, friction plates, indicator and circlip and check end play (Automatic transmission F4A41, F4A42-1 until December 1997, F4A42-2 without freewheel)

Pic. 11.3106. Install brake discs, friction plates, indicator and circlip and check end play (Automatic transmission F4A41, F4A42-1 since January 1998)

72. Install reaction disc and used circlip.

73. Using the indicator, measure the axial clearance. Based on measurements, select a circlip that provides the required clearance. Replace the circlip used in step 70 with the selected circlip. Nominal gap: 0-0.16mm.

74. Install brake discs, friction plates and indicator MB991631 (Automatic transmission F4A41, F4A42) or MB991632 (Automatic transmission F4A51) (pic. 11.311a-g).

Pic. 11.311 a. Install brake discs, friction plates and indicator MB991631 (Automatic transmission F4A41 and F4A42-1 until December 1997)

Pic. 11.311b. Install brake discs, friction plates and indicator MB991631 (Automatic transmission F4A41 since January 1998)

Pic. 11.311c. Install brake discs, friction plates and indicator MB991631 (AKPPR4A42-1 since January 1998)

Pic. 11.311 Install brake discs, friction plates and indicator MB991631 (AKPPR4A42-1 with freewheel since January 1998.)

Number of brake discs and plates

Model	Brake disk	brake plate
F4A41	2	1
F4A42	3	2
F4A51	4	3

75. Install return spring, 2nd gear detent piston and circlip.

76. Measure the axial clearance and select from tables 11.Za or 11.3b a pressure plate whose thickness will correspond to the measured axial clearance (pic. 11.312).

Rated axial clearance: automatic transmission F4A41 - 0.49-0.95 mm, automatic transmission F4A42 - 0.79-1.25 mm, automatic transmission F4A51 - 1.09-1.55 mm.

Table 11.For. Pressure plate for F4A41 and F4A42

Displacement value, mm		Thickness,	Identification label	Part No
F4A41	F4A42
0.3-0.5	0.6-0.8	1.6	L	MD759567
0.5-0.7	0.8-1.0	1.8	1	MD759414
0.7-0.9	1.0-1.2	2.0	0	MD759415
0.9-1.1	1.2-1.4	2.2	2	MD759416
1.1-1.3	1.4-1.6	2.4	4	MD759417
1.3-1.5	1.6-1.8	2.6	6	MD759418

Table 11.3b. Pressure plate for F4A51

Displacement value, mm	Thickness, mm	Identification label	Part No
1.1-1.3	1.8	E	MD759425
1.3-1.5	2.0	D	MD759426
1.5-1.7	2.2	WITH	MD759427
1.7-1.9	2.4	IN	MD759428
1.9-2.1	2.6	A	MD759429
2.1-2.3	2.8	0	MD759430

77. Turn over the gearbox.

78. Insert the stem MD998913 into the dial indicator and measure the axial clearance using the indicator MB991631 or MB991632 (pic. 11.313). Select from tables 11.4a or 11.4b a pressure plate whose thickness will correspond to the measured axial clearance.

Rated axial clearance: automatic transmission F4A41 - 1.05-1.51 mm, automatic transmission F4A42-1 - 1.35-1.81 mm, automatic transmission F4A42-2 and F4A51 - 1.65-2.11 mm.

Table 11.4a. Pressure plate for F4A41 and F4A42

Displacement value, mm			Thickness, mm	Identification label	Part No
F4A41	F4A42-1	F4A42-1
0.7-0.9	1.0-1.2	1.3-1.5	1.6	L	MD759567
0.9-1.1	1.2-1.4	1.5-1.7	1.8	1	MD759414
1.1-1.3	1.4-1.6	1.7-1.9	2.0	0	MD759415
1.3-1.5	1.6-1.8	1.9-2.1	2.2	2	MD759416
1.5-1.7	1.8-2.0	2.1-2.3	2.4	4	MD759417
1.7-1.9	2.0-2.2	2.3-2.5	2.6	6	MD759418
1.9-2.1	2.2-2.4	2.5-2.7	2.8	8	MD759419
2.1-2.3	2.4-2.6	2.7-2.9	3.0	D	MD759420

Table 11.4b. Pressure plate for F4A51

Displacement value, mm	Thickness, mm	Identification symbol	Part No
1.0-1.2	1.6	F	MD759568
1.2-1.4	1.8	E	MD759425
1.4-1.6	2.0	D	MD759426
1.6-1.8	2.2	WITH	MD759427
1.8-2.0	2.4	IN	MD759428
2.0-2.2	2.6	A	MD759429
2.2-2.4	2.8	0	MD759430
2.4-2.6	3.0	1	MD759431

79. Remove all installed measuring and additional devices.

80. Install the output shaft in the gearbox housing and tighten the bolt securing the output shaft bearing bracket to the required torque (pic. 11.304).

81. Install bushing and tapered roller bearing on output shaft (pic. 11.314).



82. Lubricate the new locknut with transmission fluid and tighten it to the required torque. Then loosen one turn and tighten again.

83. Move the output shaft to measure the end play and select the insert within the following limits (pic. 11.315): from (Axial clearance + old insert thickness + 0.01 mm) before (Axial clearance + old insert thickness + 0.09 mm).



84. Lock the locknut with a center punch (in two places) (pic. 11.316).



85. Install the lid (pic. 11.317).



86. Install the transfer case drive gear (pic. 11.308).

87. Tighten the four bolts of the transfer case drive gear (rice. 11.299).

88. Install the automatic transmission lock when parking, insert and spring. Then install the automatic transmission lock link when parking (pic. 11.318).



89. Install the automatic transmission lock support when parking and two (pic. 11.319).



90. Install the underdrive sun gear and thrust bearing onto the output shaft planetary carrier (F4A41, F4A42-1 and F4A42-2 without freewheel) (pic. 11.320).



91. Install the output shaft planet carrier and thrust bearing (F4A41, F4A42-1 and F4A42-2 without freewheel) (pic. 11.321).



92. Install the overdrive planetary carrier (F4A41, F4A42-1 and F4A42-2 without freewheel) or planetary carrier (F4A42-2 with freewheel and F4A51) (rice. 11.288).

93. Install reverse planetary sun gear (rice. 11.284).

94. Install the shaft spring (rice. 11.295).

95. Install pressure plate, brake discs and friction plates (pic. 11.322).

Number of brake discs and friction plates

Model	Brake discs	friction plates	pressure plate
F4A41	4	3	1
F4A42-1	5	4	1
F4A42-2, F4A51	6	5	1

96. Install snap ring (pic. 11.323).



97. Install Reactive Disk (pic. 11.324).



98. Install snap ring (pic. 11.325).



99. Install brake discs, friction plates and pressure plate (pic. 11.326).



100. Install the 2nd gear detent return spring and piston (rice. 11.286).

101. Install snap ring (pic. 11.327).



102. Install thrust bearing (pic. 11.328).



103. Install overdrive clutch hub and thrust bearing into reverse/overdrive clutch (pic. 11.329).



104. Install reverse/overdrive clutch and thrust bearing (pic. 11 330).



105. Install three o-rings (rice. 11.280).

106. Press the input shaft bearing into the rear cover (pic. 11.331).



107. Install four oil seals in the groove in the rear cover.

108. Install the thinnest rotating ring on the thrust bearing (thickness 1.6mm), install the rear cover and tighten the bolts to the specified torque. Measure the axial clearance of the underdrive sun gear (pic. 11.332). Nominal clearance: 0.25-0.45mm. Select from table 11.5 a rotating ring whose thickness corresponds to the measured gap and replace the previously installed one with the selected ring.

Table 11.5. Rolling ring thickness

Measured parameter, mm	Thickness, mm	Part No
0.3-0.4	1.6	MD707267
0.4-0.5	1.7	MD759681
0.5-0.6	1.8	MD723064
0.6-0.7	1.9	MD754794
0.7-0.8	2.0	MD707268
0.8-0.9	2.1	MD754795
0.9-1.0	2.2	MD723065
1.0-1.1	2.3	MD754796
1.1-1.2	2.4	MD724358
1.2-1.3	2.5	MD754797
1.3-1.4	2.6	MD754798

109. Install the back cover (pic. 11.279).

110. Install the underdrive clutch hub (pic. 11.278).

111. Install thrust bearing (pic. 11.333).



112. While holding the input shaft, install the underdrive clutch (rice. 11.276).

113. Install two pieces of solder wire (each 10 mm long and 3.5 mm in diameter) on with downshift clutch hub (pic. 11.334).



114. Install the special tool and install the oil pump in the gearbox housing (pic. 11.335).



115. Tighten and loosen the oil pump mounting bolts (6 items).

116. Using the special tool, remove the oil pump (rice. 11.274). After that, remove the compressed pieces of solder wire. Measure the thickness of the compressed wire with a micrometer. Select from table 11.6 a thrust disk whose thickness corresponds to the measured clearance.

Table 11.6. Thrust plate thickness

Measured value, mm	Thickness, mm	Identification label	Part No
2.25-2.45	1.8	18	MD754509
2.45-2.65	2.0	20	MD754508
2.65-2.85	2.2	22	MD754507
2.85-3.05	2.4	24	MD753793
3.05-3.25	2.6	26	MD753794
3.25-3.45	2.8	28	MD753795

117. Install the thrust plate thus selected into the underdrive clutch bracket (rice. 11.275).

118. Install a new oil pump gasket and oil pump.

119. Tighten the oil pump mounting bolts.

120. Check the axial clearance of the input shaft, which must correspond to the required (pic. 11.336). Required clearance: 0.70-1.45 mm.



121. Install the oil filter (rice. 11.272).

122. Install insert (only for automatic transmission F4A41-1-MRA) and then differential (Automatic transmission F4A41) (rice. 11.270).

123. Install differential (Automatic transmission F4A42, F4A51) (pic. 11.271).

124. Install the 1.25 mm thick insert (only for automatic transmission F4A41-1-MRA).

125. Install solder wire 10 mm long and 3 mm in diameter on the differential (Automatic transmission F4A41) (pic. 11.337).



125. Apply solder wire 10 mm long and 3 mm in diameter and the outer rotating ring, as shown in figure TFA1527, to the transformer housing (F4A42, F4A51).

126. Install the GTR body without sealant into the automatic transmission crankcase and tighten its fastening bolts to the required tightening torque.

127. Unscrew the bolts, remove the outer rotating ring (Automatic transmission F4A42, F4A51) and solder wire.

128. Using an indicator, measure the thickness of the compressed solder wire (rice. 11.15). Select an insert whose thickness must be within the range defined by the following formula:

• Automatic transmission F4A41: from (T -0.045 mm) before (T -0.165mm).
• Automatic transmission F4A42, F4A51: from (T +0.045 mm) before (T +0.105 mm).

130. Install the selected insert (Automatic transmission F4A41) (rice. 11.270).

131. Install strainer and 2nd detent bracket oil seal (rice. 11.265).

132. Install the solenoid valve wiring connector and circlip (rice. 11.264).

133. Install valve block, gasket and two steel balls (rice. 11.263).

134. Install the oil temperature sensor (rice. 11.262).

135. Tighten 28 bolts of fastening of the block of valves.

136. Connect the wiring connectors to the valve block (rice. 11.261).

137. Install the spring and the latch of the gear lever (rice. 11.260a,b).

138. Establish a cover of the block of valves and tighten bolts of its fastening (rice. 11.259).

139. Install the speedometer gear or cap (rice. 11.258).

140. Install the starter interlock switch and shift lever (rice. 11.257).

141. Install the speed sensors of the primary and secondary shafts (rice. 11.256).

142. Install the oil level indicator.

143. Next, the assembly is carried out in the reverse order of removal.

№	Knot	Wire color	Wiring connector color
1	Underdrive solenoid valve	White, red, red	Black
2	Overdrive solenoid valve	Orange, red	Black
3	1st/Reverse solenoid valve	Brown, yellow	milky white
4	2nd brake solenoid valve	Green, red, red	milky white
5	Damper clutch control solenoid valve	Blue, yellow, yellow	Black
6	Oil temperature sensor	Black red	Black