Page 51
4. Turn the ignition key back and forth to
make sure that the gear lever lock
does not stick or jam.
5. Fit the cover plate.
6. Fit the gear lever housing. (5-speed
models only: Hook the spring onto the
contro] unit.)
7. Connect the leads to the ignition
switch and reversing light switch.
8. Fit the heater duct and fold down the
carpet.
9. Fit the centre console.
10. Refit the seat.
ll. Reconnect the battery leads.
Lock cylinder
Removing
1. Remove the gear lever housing (see the
section on removing the gear lever
housing).
2. Turn the key to a position mid-way
between the locking and garage posi-
tions.
3. With the key in this position, the lock
cylinder dowel can be pushed in to free
the cylinder using a wire lockpick or
similar inserted through a hole under
the gear lever housing (see illustration).
4. Pull out the lock cylinder.
Assembling
1. Turn the key in the lock cylinder to a
position between the locking and garage
positions.
2. Push in the lock cylinder dowel. Check
that the toothed segment driver pins
are correctly positioned to fit in the
lock cylinder. Push in the lock cylinder
and check that it is engaged in the
toothed segment.
3. Fit the gear lever housing (see Gear
lever housing Assembling).
Removing the cylinder when the key is
missing
To remove the lock cylinder from the gear
lever housing when the key is missing
(thereby demolishing the lock cylinder),
proceed as follows:
1. Remove the left front seat and the gear
lever cover.
2. Remove the centre console.
3. Drill out the plug covering the hole for
the lock cylinder dowel in the gear
lever housing.
4. Drive in the dowel using a drift (approx.
0.08 in. or 2 mm) and remove the lock
cylinder.
432-3
Page 52
Gear lever
up to and incl. chassis no.
90 80 102 3498
90 80 200 7076
90 80 600 2627
Removal
1. Undo the three screws under the rubber
boot and remove the gear lever from
the gear lever housing.
2. Pull out the bellows dowel from the
sleeve, screw out the catch stud and
remove the spring.
3, Remove the sleeve, the bearing and the
cover.
4. Tap the knob carefully with a plastic
mallet, so that it will loosen from the
gear lever and remove the sleeve, the
eatch rod and the rubber boot.
5. Remove the circlip which holds the
hollow lever and the gear lever to-
gether and pull out the hollow lever
with its rubber bush.
Replace damaged or worn parts.
Assembly
l.
2.
Fit the slot ring, washers and rubber
bushes to the hollow lever.
Fit the hollow lever to the gear lever
and fit the circlip.
Fit the rubber boot, sleeve and catch
rod. Fit the spring into the hollow lever
and screw in the catch stud as shown in
the figure, so that the dimension shown
will be obtained.
Fit cover, bearing, sleeve and hollow
dowel.
Press the knob onto the gear lever.
. Fit the gear lever to the gear lever
housing.
Section through gear lever housing
1. Knob 13. Circlip
2. Sleeve 14. Cover
3. Catch rod 15. Bearing
4. Gear lever 16. Gear lever bearing
5, Rubber boot 17. Carrier
6. Rubber bush 18. Hollow dowel
7. Washer 19. Spring
8. Hollow lever 20. Gear shift rod
9. Slot ring 21. Catch stud
10. Washer 22. Bottom part
11. Rubber bush 23. Bearing
12. Washer 24. Rubber bush
432-4
SS
=
a
Page 53
Gear lever, 5-speed models
As from chassis No.
90 80 102 3499
90 80 200 7077
90 80 600 2628
Removal
l.Remove the gear lever from the gear
lever housing.
2.Remove the hollow dowel and remove
the sleeve, spring and bearing campo-
nents.
3.Unserew the eatch stud from the catch
rod.
4.Remove the rubber boot from the
sleeve.
5.Prise away the knob from the hollow
lever.
6.Remove the sleeve and the catch rod.
Assembly in the reverse order.
Note
Before the hollow dowel is fitted, the
projecting length of the catch stud
must be adjusted to 26.5 + 0.5 mm.
Gear lever housing
1. Knob
2. Gear lever
3. Stop ring
4, Sleeve
5. Catch rod
6. Rubber boat
7. Cover
8. Bearing
9. Spring
10. Hollow dowel
11. Spring
12. Catch stud
13. Carrier
432-8
—
iy
—_a —
a oO ~
Page 54
Centre console as from 1983 models
To remove
1.Move the seats to the rear limit of
their fore-and-aft adjustment and apply
the handbrake.
2.Engage reverse gear and remove the
ignition key.
3.Remove the handle for the choke
control (cars with careburettor en-
gines). Then push the control in.
Remove the Ww the
handle.
4.Remove the two screws for the cover
(top part of the console) and raise the
cover so that the cables can be discon-
ev nected from the switch for the interior
lighting.
Then release the cover from the gear
lever,
we)
Remove the rubber boot of the gear lever
from the top part af the console.
Ww
-Remove the ashtray located at the rear
of the console. Remove the five screws.
Raise the console and remove the lamp
for the ignition lighting. The console
can then be released from the gear
lever.
wv Assemble in the reverse order.
Note
On Turbo and GLE cars, the bellows
between the centre console and the
radio console can be removed and
refitted separately.
Page 55
| Gear lever
Removal
l.Remove the gear lever from the gear
lever housing.
2.Remove the hollow dowel and remove
the sleeve, spring and bearing compo-
nents.
3.Unscrew the catch stud from the catch
rod.
4.Remove the rubber boot from. the
sleeve.
5.Prise away the knob from the hollow
lever.
6.Remove the sleeve and the catch rod.
140
Assembling
Assembly in the reverse order.
Note
Before the hollow dowel is fitted, the
projecting length of the catch stud
must be adjusted to 22.5 4 0.5mm
- 0.0 mm
€
Gear lever
1. Knob
2. Gear lever
3. Sleeve
4. Catch rod
5. Rubber boot
wy 6. Cover
7. Bearing
8. Spring
9. Hollow dowel
10. Spring
wy 11. Catch stud
12. Carriers
13. Bearing
$465
432-13
Page 56
Fault diagnosis schedule related to the test
report on the automatic transmission
* If the warranty is still in force, the
automatic transmission should be replaced
by. a replacement unit.
Test No.
0.1
Does not drive
Line pressure too
low or no pressure
0.2
Does not drive
Mechanical defects.
Line pressure OK,
Led
Pulls away in 2nd
1.2
Pulls away in 3rd
Led
Low upshift speed
1.4
High upshift speed
A.
B.
C.
D.
E.
A.
B.
D.
As
B.
Cc.
D.
B.
Check the oi! level in the automatic transmission
Oil filter clogged by impurities
Suction pipe O-ring leaking
*
Torque converter drive lugs broken
Check the selector control, also in the automatic transmission
Check the primary drive and final drive
Check that the pipes are firmly secured
*
Does not drive in"D". Check the front clutch. Check the
one-way clutch.
Does not drive in"R". Check the rear clutch, rear band
and rear servo
Check the governor for binding
Check the 1-2 shift valve for binding
*
Dismantle the transmission, check the governor mounting
- seal rings
Replace the governor assembly (internal leakage)
Replace the valve body assembly (internal leakage)
Check the governor for binding
Check the 1-2 and 2-3 shift valves for binding
*
Dismantle the transmission, check the governor mounting
- seal rings
Replace the governor assembly (internal leakage)
Replace the valve body assembly (internal leakage)
Check that the kick-down valve cable is correctly adjusted
Check whether the idling speed pressure is too low
Check the governor for binding
+=
Replace the governor (correct type)
Check that the kick-down valve cable is correctly adjusted
Check whether the idling speed pressure is too high
Check the governor for binding
Check the pipes between the governor and the valve body
*
Replace the governor (correct type)
Dismantle the transmission, check the governor mounting
- seal rings
Page 57
Test No.
15
Does not shift up
2.1
Juddering or noise
on manual shifting
(1st)
me
Upshift from
manual (1st)
2.3
No overrun braking
in manual (1st)
Del
Slips ona
gradient
4.1
Pulls away in 2nd
4.2
Pulls away in 3rd
A.
B.
C.
D.
Es
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
B.
Cc.
Os
Ee
F.
A.
B.
Cc.
D.
E.
F.
Check that the kick-down valve cable is correctly adjusted
Check the kick-down valve cable (seized in the kick-down
position)
Check the pipes between the governor and valve body
Check the shift valves for binding
Check the governor for binding
*
Check that the governor faces in the correct way (BW35)
Check that the gear selector cable is correctly adjusted
Check the oil level
Check that the rear band is correctly adjusted
Check the pipes to the rear servo
*
Check the O-rings of the N-D accumulator
Check the O-rings of the rear servo
Check the front clutch
Check that the gear selector cable is correctly adjusted
Check that the rear band is correctly adjusted
Check the pipes to the rear servo
*
Check the O-rings of the rear servo piston
Dismantle the transmission and check the rear band
Check that the kick-down valve cable is correctly adjusted
Check the oil level
Check that the rear band is correctly adjusted
Check whether the idling speed pressure is too low
Check the pipes to the rear servo and rear clutch
*
Check the O-rings of the rear servo piston
Dismantle the transmission, check the rear servo and rear
clutch
Check the rear band
Check the rear clutch seals (three)
Check the governor for binding
Check the 1-2 shift valves for binding
*
Dismantle the transmission, check the governor mounting
- seal rings
Replace the governor assembly (internal leakage)
Replace the valve body assembly (interna! leakage)
Check the governor for binding
Check the 1-2 and 2-3 shift valves for binding
*
Dismantle the transmission, check the governor mounting
- seal rings
Replace the governor assembly (internal leakage)
Replace the valve body assembly (internal leakage)
Page 58
Test No.
4.3
Low upshift speed
on kick-down
4.4
High upshift speed
on kick-down
4.5
Does not shift
down
4.6
Slips on shifting
5.1
Low 3-1/3-2
shift speed
on kick-down
Jae
High 3-1/3-2
shift speed
on kick-down
5.3
No 3-1 shift
on kick-down
5.4
No 3-2 shift
on kick-down
A.
o
OD>
moO
Check that the kick-down valve cable
is withdrawn by 45 mm on kick-down
Check the governor for binding
+
Check the governor for binding
Check the pipes between the governor and the valve body
Check the shift valves for binding
*
Check the seal rings of the governor mounting
Check the governor for binding
Check the pipes between the governor and the valve body
Check the shift valves for binding
*
Dismantle the transmission, check the seal rings of the
governor mounting
Check that the front band is correctly adjusted
Check the pressure drop before shifting (after cut-back
- ACB) (adjustment of the kick-down valve cable)
*
Check the O-rings of the front servo piston
Check the front clutch, front band and rear clutch
Check the seals on the sun gear shaft
Check that the kick-down valve cable is withdrawn by
45 mm on kick-down
Check the governor for binding
Check that the kick-down valve cable is correctly adjusted
*
Check the governor for binding
*
Check that the kick-down valve cable is withdrawn by
45 mm on kick-down
Check the governor for binding
Check the 1-2 and 2-3 shift valves for binding
oi
Check that the kick-down valve cable is withdrawn by
45 mm on kick-down
Check the governor for binding
Check that the front band is correctly adjusted
Check the 1-2 and 2-3 shift valves for binding
*
440—49
Page 59
Test No.
5:9 A.
Slips on shifting B.
Cc.
D.
E.
F.
G.
6.1 A.
No overrun braking B.
on manual shifting C.
(2nd)
6.2 A.
No overrun braking B.
on manual shifting C.
(1st) D.
E.
F.
6.3 A.
Manual downshift
(1st) at 80 km/h B.
Tek A.
Pulls forward B.
slightly Cc.
8.1 A.
The parking paw! iB.
does not hold
Cc.
D.
9.1 A.
Does not normally
shift B.
Cc.
D.
Es
Fs
G.
Check that the front band is correctly adjusted
Check that the kick-down valve cable is correctly
adjusted
Check the mounting of the pipes (leakage)
*
Check the O-rings of the front servo piston
Check the front clutch, front band and rear clutch
Check the seals on the sun gear shaft
Check that the gear selector cable is correctly adjusted
Check that the front band is correctly adjusted
*
Check that the gear selector cable is correctly adjusted
Check that the rear band is correctly adjusted
Check the rear servo pipes
*
Check the O-rings of the rear servo piston
Check the rear band
Check that the throttle cable has not seized in the
kick-down position
Check the line pressure
Check the kick-down valve
*
Replace the valve body
Check that the gear selector cable is correctly adjusted
Check the O-rings of the N-D accumulator
Check the position of the manual valve in the valve body
in op
*
Dismantle the transmission and check the front clutch
springs
Check that the gear selector cable is correctly adjusted
Check that the gear selector rod is correctly adjusted
(remove the cover)
Check the parking paw! and ring gear
*
Check that the kick-down valve cable is correctly
adjusted
Check the oil level
Check that the gear selector cable is correctly adjusted
Check that the front band is correctly adjusted
Check that the rear band is correctly adjusted
*
Dismantle the transmission, and check all bands and clutches
Page 60
es
10.1
Noise
a ES
Leakage
Test No.
Check the oil in the final drive
Check the ATF oil! level
Check that the gear selector cable is correctly adjusted
(the parking pawl engages in the ring gear)
*
Check the drive disc (for cracks, loose bolts)
Check the oi! cooler outlet
Dismantle the transmission and check the needle bearings
and pinion bearings (the pinion bearing noise is
transmitted through the selector lever)
Check the planet gear (tooth damage - thrust washers)
Check that torque converter (drain the remaining ATF
and look for loose parts)
Check the oil pump (centring, drive, noise)
Chain (primary drive) and sprockets
Note that noise may originate from other parts of the
power unit and auxiliaries,
Covers; change the gaskets, refit and tighten with the
appropriate torque
Replace the pump seal with the transmission in the car
*
Gasket between the torque converter housing and gearcase.
Remove the transmission.
Sealing cover between the torque converter housing and
gearbox (O-rings or porosity)
Pinion bearing seals (drain hole on the BW 37)
440-51