Mitsubishi Galant

1990 — 2001 of release

Repair and car operation



Mitsubishi Galant
+ Identification numbers of the car
+ Governing bodies
+ Settings and routine maintenance
+ Engine
+ cooling and heating Systems
+ Power supply system and release
+ engine Electric equipment
+ Control systems of the engine
- Manual transmission
   + 5-step manual box of gear shifting (RKPP)
   - Automatic transmissions (AT)
      General information and functioning principle
      AT problem diagnostics - the general information
      The adjustments made without removal of AT from the car
      Removal and installation of the pallet of a case of AT
      Removal, installation and adjustment of the sensor switch of permission of start
      Removal and AT installation
      Major maintenance of AT
   + Transfer case
+ Coupling and transmission line
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment





Major maintenance of AT

AT F3А21 design

1 — a management Cable
2 — the Spring washer
3 — the Control lever
4 — the Clamp
5 — the PNP Sensor switch
6 — the Holder of the bearing
7 — the Sealing ring
8 — the Lock ring
9 — the Lock level
10 — the Sealing ring
11 — the Axis of an intermediate gear wheel
12 — the Internal holder of the bearing
13 — the Intermediate gear wheel
14 — the Remote ring
15 — the Clamp
16 — the Lock ring
17 — the Cover of a distributing shaft
18 — the Lock ring
19 — the Conducted gear wheel
20 — the Lock ring
21 — the External holder
22 — the Internal holder of the bearing
23 — Sealing laying
24 — the Lock ring
25 — the Coupling of the servo-driver of the kickdown mode
26 — the kickdown servo-driver Piston

27 — the Spring
28 — the Anchor rod
29 — the Target flange
30 — the Remote ring
31 — the External holder
32 — the Distributing shaft with operating regulator
33 — the hydroaccumulator Piston
34 — the Internal spring
35 — the External spring
36 — the Sealing ring
37 — the Sealing ring
38 — the Adjusting screw
39 — the Sealing ring
40 — the Fixing ball
41 — the Spring
42 — Rasporny an AT parking situation rod
43 — the Emphasis of a rasporny rod
44 — a management Rod
45 — Klapannaya assembly
46 — the Oil filter
47 — Sealing laying
48 — the case Pallet
49 — sealing laying
50 — the Drain stopper
51 — Carter of transmission


Design of internal components of transmission of F3А21

1 — the rotation Converter
2 — a converter Dome
3 — Sealing laying
4 — the Oil pump
5 — the Sealing ring
6 — Sealing laying
7 — the Persistent washer No. 1
8 — Assembly of the forward coupling of coupling
9 — the Persistent holder No. 3
10 — the Persistent bearing No. 4
11 — the Persistent washer No. 2
12 — Assembly of the back coupling of coupling
13 — the Remote ring
14 — Differential
15 — the Persistent bearing No. 6
16 — the Nave of the coupling of coupling
17 — the Persistent holder No. 7
18 — the Persistent bearing No. 8
19 — the Brake tape of inclusion of the kickdown mode

20 — the Brake drum of inclusion of the kickdown mode
21 — the Lock ring
22 — the Central emphasis
23 — the Sealing ring
24 — the Wavy washer
25 — the Returnable spring
26 — Press a disk
27 — Brake disks
28 — Brake plates
29 — the Jet plate
30 — the Solar gear wheel of a reverse gear
31 — the Persistent bearing No. 9
32 — the Persistent holder No. 10
33 — the Solar gear wheel of forward transfers
34 — the Holder of planetary transfer
35 — the Persistent bearing No. 12


Design of transmission of the F4А20 series

1 — the Pulse generator
2 — the Spring washer
3 — the Control lever
4 — the Clamp
5 — the PNP Sensor switch
6 — the Sensor of temperature of ATF
7 — the Cover of the face coupling of coupling
8 — the Sealing ring
9 — the Bearing
10 — the Face coupling of coupling
11 — the Persistent washer
12 — the Nave of the face coupling of coupling
13 — the Persistent bearing No. 13
14 — the Axis of the face coupling of coupling
15 — the Holder of the bearing
16 — the Lock ring
17 — the Lock level
18 — the Axis of an intermediate gear wheel
19 — the Internal holder of the bearing
20 — the Intermediate gear wheel
21 — the Internal holder of the bearing
22 — the Remote ring
23 — a lock ring
24 — the kickdown servo-driver Sensor switch
25 — the kickdown servo-driver Piston
26 — the Spring
27 — the Anchor rod
28 — the Target flange

29 — the Distributing shaft
30 — the External holder
31 — Sealing laying
32 — the Sealing ring
33 — the Clamp
34 — Klapannaya assembly
35 — the Clamp
36 — Sealing laying
37 — the case Pallet
38 — Sealing laying
39 — the Drain stopper
40 — the Sealing ring
41 — the Adjusting screw
42 — the Sealing ring
43 — a clamp Ball
44 — a clamp Saddle
45 — a clamp Spring
46 — the Emphasis of a rasporny rod
47 — Rasporny a rod of parking provision of transmission
48 — a management Rod
49 — the Sealing ring
50 — the Cover of a distributing shaft
51 — the Lock-nut
52 — the Conducted gear wheel
53 — the External holder
54 — the Remote ring
55 — Carter of transmission


The scheme of an arrangement of persistent bearings, holders and washers on F3А21 transmission

 

The scheme of an arrangement of persistent bearings, holders and washers on F4А20 series transmissions

 


Major maintenance of AT means need of performance of a large number of precision measurements, demands from the performer of ability to use the special tool and, in view of told, its performance lies outside the limits of qualification of the average amateur mechanic.

For sure the fluent description of procedures of dismantling and AT assembly is provided in the strengths of motorists in the present Section, and also the illustrative material on a design of separate, most typical components of transmission is given.

AT dismantling

F3А21 transmission

 PERFORMANCE ORDER

It is supposed that transmission is already removed from the car and transferred on an assembly stand/workbench.

1. The design of AT F3А21 is presented on illustrations.
2. Before starting transmission dismantling, закупорьте all openings in a case and carefully wipe an external surface of the last. Remove the converter of rotation and overturn transmission by the pallet down.
3. Measure sizes axial люфта primary shaft, uncover a distributing shaft and measure size axial люфта the last. Write down results of measurements.

4. Remove the sensor switch of permission of start (see. Section Removal, installation and adjustment of the sensor switch of permission of start).
5. Remove the case pallet with sealing laying and the filter.
6. Remove the sensor of temperature of ATF, push the plug of a plait of electroconducting of the electromagnetic valve through passage and the contact socket of the last in a transmission case.

7. Disconnect a cable of a drive of a butterfly valve, then turn out fixing bolts and remove klapanny assembly.

Try not to allow losses from assembly of the manual valve! Do not forget to remove the sealing ring established between assembly by the case of assembly and a case of transmission, - the ring is subject to replacement without fail. Remove the piston and accumulator springs.

8. Remove a dome of the converter of rotation, assembly of the oil pump and a persistent washer. Remove differential assembly with a remote ring. Remove primary shaft of AT assembled with forward and back couplings of coupling.
9. Remove the plug of the persistent bearing and a nave of the coupling of coupling. Remove a persistent washer and the bearing. Remove a drum and a tape of the mechanism of inclusion of the kickdown mode. Remove a lock ring, the piston, a spring and an anchor rod of the kickdown servo-driver.
10. Remove assembly of planetary transfer.
11. Remove wavy and returnable springs, press, brake both jet disks and plates.

Try to remember the adjusting provision of a returnable spring.

12. Turn out a bolt and remove a lock plate of an axis of an intermediate gear wheel of the distributing mechanism. By means of a special key (MD998334) remove an intermediate gear wheel. Remove two internal holders of the bearing and a remote ring of a gear wheel.
13. Remove the holder of the bearing of a target flange with a sealing ring. Remove a lock ring from an external holder of the bearing. Remove an internal gear wheel assembled with a target flange, a leading gear wheel of the distributing mechanism and the bearing.
14. Remove a lock ring from a back pin distributing фала. Having rested a brass drift against a back end face of a shaft, begin to knock the last aflush with a surface interfaced to the engine, - the conducted gear wheel of the distributing mechanism should act in film.
15. Take a lock ring, then (in case of need) remove internal and external holders of the konusny roller bearing. Remove an emphasis of a rasporny rod and a shaft of manual control, take a steel ball and a spring.


Transmissions of the F4А20 series (F4A22/23/33/51)

 PERFORMANCE ORDER

It is supposed that transmission is already removed from the car and transferred on an assembly stand/workbench.

1. The design of AT of the F4A20/30/50 series is presented on illustrations.
2. Before starting transmission dismantling, закупорьте all openings in a case and carefully wipe an external surface of the last. Remove the converter of rotation and overturn transmission by the pallet down.
3. Measure size axial люфта primary shaft. Write down result of measurement.

4. Remove pulse generators A and B and the PNP sensor switch.

5. Remove the sensor switch of the servo-driver of the kickdown mode.
6. Remove the case pallet with sealing laying and the filter. Remove the sensor of temperature of ATF.
7. Disconnect electroconducting from the electromagnetic valve and remove klapanny assembly.
8. Remove a face cover and the coupling of coupling located under it.
9. Remove a nave of the face coupling, the persistent bearing and a coupling axis.
10. Remove a dome of the converter of rotation, assembly of the oil pump and a persistent washer.
11. Remove differential assembly with a remote ring.
12. Remove primary shaft assembled with forward and back couplings of coupling.
13. Remove the persistent bearing and a nave of the coupling of coupling. Remove a persistent holder and the bearing.
14. Remove a tape and a drum of the brake mechanism of the kickdown mode.
15. Remove the holder, the piston and a kickdown servo-driver spring. Remove an anchor rod. Remove a lock ring and the central emphasis. Remove solar gear wheels of lobbies and back transfers. Remove the holder of planetary assembly with the bearing. Remove a persistent holder and the bearing. Remove a wavy washer, a returnable spring, press a disk brake disks/plates and a jet plate, - try to remember the adjusting provision of a returnable spring.
16. Remove the holder of the face bearing, - in case of need use a drift.
17. Turn out a bolt and remove a lock plate of an axis of an intermediate gear wheel of the distributing mechanism. By means of a special key (MD998334) remove an intermediate gear wheel. Take an axis of an intermediate gear wheel and remove two internal holders of the bearing and a remote ring of a gear wheel.
18. Remove a lock ring of the face bearing. Take from a case assembly of an internal gear wheel with a target flange, a leading gear wheel of the distributing mechanism and the bearing. Uncover a distributing shaft.
19. Release a lock-nut of a distributing shaft (the nut has the left carving). By means of a press squeeze out a shaft. By means of a stripper dismantle the bearing of a distributing shaft. Turn out the adjusting screw and remove a manual rod of management with an emphasis of a rasporny rod.


Service of separate components

 PERFORMANCE ORDER

1. As it was already mentioned above, in view of complexity of procedures of service of AT components at its major maintenance, it is necessary to charge performance of the last to specialists of firm station of car-care center of the Mitsubishi company.
2. The illustrative material allowing the reader having technical education to make general idea about a design and an assembly order and service of separate knots and components of automatic transmission is given in the present Section. Besides, some adjusting parameters and dimensional characteristics are specified.


Oil pump ATF

Design of the oil pump

1 — the Epiploon
2 — the Case
3 — the Sealing ring
4 — the Leading gear wheel
5 — the Epiploon

6 — the Lock ring
7 — the Conducted gear wheel
8 — the Support of a jet shaft
9 — Sealing rings
10 — the Control ball


 PERFORMANCE ORDER

Track, that at assembly fixing bolts were tightened with demanded effort; in summary check freedom of rotation of gear wheels of the pump.


Forward coupling of coupling

Design of the forward coupling of coupling of AT

1 — the Holder of the forward coupling
2 — Sealing rings
3 — the Piston of the forward coupling
4 — the Returnable spring

5 — Cтопорное a ring
6 — Jet plates of coupling
7 — the Lock ring (steals up)
8 — coupling Disks


 PERFORMANCE ORDER

At assembly see, that the gap between a lock ring and a jet plate of assembly corresponded to requirements of Specifications, - lock rings of various thickness in a range of 1.6 ÷ 3.0 mm with a step of 0.10 mm are issued. do not forget to replace sealing rings.


Back coupling of coupling

Design of the back coupling of coupling of AT

1 — Sealing rings (3)
2 — the Holder of the back coupling
3 — the Epiploon
4 — the Piston of the back coupling
5 — the Sealing ring
6 — the Wavy washer
7 — coupling Disks
8 — the Lock ring

9 — the Persistent holder
10 — the Lock ring
11 — the Jet plate
12 — a coupling Plate
13 — Press a disk
14 — the Returnable spring
15 — the Sealing ring


 PERFORMANCE ORDER

Adjustment of a gap of landing of a lock ring is made by selection of a ring of the corresponding thickness. Track combination of an oil flute of primary shaft from the basic well-aimed holder of the coupling. Do not forget to replace sealing rings.


Face coupling of coupling (only F4А20 series transmissions)

Design of the face coupling of coupling (only F4А20 series transmissions)

1 — the Lock ring
2 — the Jet plate
3 — coupling Plates
4 — the Lock ring
5 — the Washer
6 — the Returnable spring

7 — the coupling Piston
8 — the Sealing ring
9 — the Epiploon
10 — the Holder of the face coupling
11 — the Sealing ring
12 — coupling Disks


 PERFORMANCE ORDER

In this coupling the lock ring steals up from a range of thickness 1.05 ÷ 2.05 (a step = 0.25 mm). Do not forget to replace sealing rings.


Brake assembly of low gears and reverse

 PERFORMANCE ORDER

Do not forget to replace a sealing ring.


Planetary assembly

Design of planetary assembly of AT

1 — the Blocking plate
2 — the External holder of the one-pass coupling
3 — the Face plate
4 — the One-pass coupling
5 — the Persistent bearing
6 — the Holder of planetary assembly

7 — the Axis of satellites
8 — Forward persistent washers
9 — the Remote plug
10 — the Roller
11 — the Satellite


 PERFORMANCE ORDER

Track correctness of landing of the one-pass coupling in an external holder. All fixture tighten with demanded effort.


Internal gear wheel and distributing assembly

Internal gear wheel and distributing assembly

1 — the Internal gear wheel
2 — the Lock ring
3 — the Bearing
4 — the Bearing
5 — the Lock ring

6 — the Target flange
7 — the Flute
8 — the Leading gear wheel of distributing assembly
9 — the Leading gear wheel of distributing assembly
10 — the Adjusting direction


 PERFORMANCE ORDER

The nominal thickness of a lock ring of a target flange makes 0 ÷ 0.06 mm.


Distributing shaft and assembly of an operating regulator (F3А21 transmission)

Assembly of a distributing shaft and operating regulator of transmission of F3А21

1 — Gruzik of a regulator
2 — the Lock ring
3 — the regulator Valve
4 — the Spring
5 — the Plate of a spring
6 — the Regulator

7 — the Sealing ring (3)
8 — the Bearing
9 — the Distributing shaft
10 — the Filter
11 — the Lock-nut
12 — the Adjusting screw


 PERFORMANCE ORDER

Track observance of demanded efforts of a tightening of fixture.


Differential

Design of differential of AT

1 — the Bearing
2 — the Axis of satellites
3 — the Lock pin
4 — the Washer
5 — Satellites

6 — Remote rings
7 — the Conducted gear wheel of the main transfer
8 — Lateral gear wheels of differential
9 — a differential Box


 PERFORMANCE ORDER

1. At replacement of lateral gear wheels use remote rings of average thickness (0.93 ÷ 1.00 mm).
2. Люфт gearings of gear wheels it should be identical in both directions and not fall outside the limits a range of 0.03 ÷ 0.15 mm, - adjustment is made by selection of remote rings. Rings of the next thickness are issued: 0.75 ÷ 0.82 mm; 0.83 ÷ 0.92 mm; 0.93 ÷ 1.00 mm; 1.01 ÷ 1.08 mm and 1.09 ÷ 1.16 mm.


Piston of the servo-driver of the kickdown mode

Design of the piston of the servo-driver of the kickdown mode

1 — the Sealing ring
2 — the Stopper
3 — the Spring
4 — the Valve
5 — the Pin

6 — the Cover
7 — the Sealing ring
8 — the servo-driver Piston
9 — the Screw


 PERFORMANCE ORDER

Before assembly moisten components with transmission liquid.


Gear wheel of a drive of a speedometer

 PERFORMANCE ORDER

 

The Podpruzhinenny pin, epiploon and sealing ring are subject to replacement without fail. Before installation slightly grease a conducted gear wheel with impellent oil.

Klapanny assembly

At all do not clamp the case of klapanny assembly in a vice, - the slightest its deformation can lead to jamming of valves and development of leaks! Before installation carefully wash out all components in pure ATF and do not wipe them rags.


АТ F3А21

Dismantling

Design of klapanny assembly of AT F3А21

1 — the kickdown Valve
2 — a kickdown valve Spring
3 — the Throttle valve
4 — the Spring of the throttle valve
5 — the Persistent clamp
6 — the Sealing ring
7 — the Sealing ring
8 — the Valve of management of ranges
9 — the Spring of the valve of management of ranges
10 — the Valve of management of the converter of rotation
11 — the Spring of the valve of management of the converter of rotation
12 — the regulator Valve
13 — the Spring of the valve of a regulator
14 — the Adjusting screw
15 — the Filter
16 — the Valve of switching of 1/2 transfers
17 — the Spring of the valve of switching of 1/2 transfers
18 — the Lock ring
19 — the Valve of management of 2/3 transfers
20 — the Spring the valve of management of 2/3 transfers
21 — the Valve of a mode of braking by the engine
22 — Sealing laying
23 — the Forward face plate
24 — Sealing laying
25 — the Forward face cover
26 — the Spring of the valve of switching of 2/3 transfers
27 — the Valve of switching of 2/3 transfers
28 — Assembly of a throttle cam
29 — Spring directing

30 — the Top dividing plate
31 — the Steel ball
32 — the Spring of dumping of pressure in lines
33 — the Spring of dumping of low pressure
34 — the Intermediate plate
35 — the Bottom dividing plate
36 — the Lock clamp
37 — the Bottom section of klapanny assembly
38 — the Filter
39 — Reduktsionny the valve
40 — the accumulator Valve
41 — the Spring of the reduktsionny valve
42 — the Spring of the valve of the accumulator
43 — the Spring of the valve of the accumulator
44 — the Stopper of the valve of the accumulator
45 — the Plug
46 — the Operating valve of coupling
47 — the Spring of the operating valve
48 — the Face cover
49 — the Intensifying plate
50 — the Top section of klapanny assembly
51 — the Stopper of the valve of switching of 2/3 transfers
52 — the Stopper of the valve of switching of 1/2 transfers
53 — a regulator Stopper
54 — a regulator Stopper
55 — the Manual valve
56 — the Back face cover
57 — Sealing laying


 PERFORMANCE ORDER

1 Design of klapanny assembly of transmission of F3А21 is presented on an illustration.
2 Remove assembly of a throttle cam. Turn out 13 fixing bolts and remove the bottom section of klapanny assembly with the bottom dividing plate.
3 Remove a spring of dumping of pressure in lines and 3 steel balls. Divide the bottom klapanny assembly and an intermediate plate. Remove from the top assembly of 4 steel balls. Remove the electromagnetic valve, strengthening plate and the top dividing plate. Remove from an intermediate plate a steel ball and a spring.


Check of a condition of components and assembly

 PERFORMANCE ORDER

1. Carefully wash out all components of assembly in ATF and do not wipe them then rags. Check a condition of working surfaces of valves and the assembly case.
2. Estimate a condition of klapanny springs. Measure height of springs and compare result of measurement to requirements of Specifications. In case of need make replacement.
3. Grease with transmission liquid and establish on the regular places all valves and klapanny springs. Screw and tighten jams.
4. Track, that all fixing bolts were tightened with demanded effort. At a joint of the top and bottom sections of assembly do not forget to establish steel balls and directing pins.


F4А20 series AT

Dismantling

Design of klapanny assembly of AT of the F4А20 series

1 — the Valve of management of pressure
2 — the Spring of the valve of management of pressure
3 — the Valve of management of the converter of rotation
4 — the Spring of the valve of management of the converter
5 — the regulator Valve
6 — the Spring of the valve of a regulator
7 — the Adjusting screw
8 — the Lock clamp
9 — the Stopper of valves of management of switching
10 — the Spring
11 — the Spring of the final valve of the back coupling of coupling
12 — the Final valve B of the back coupling of coupling
13 — the Final valve A of the back coupling of coupling
14 — the Valve of switching of 2/3 and 3/4 transfers
15 — the Spring of the valve of switching of 2/3 and 3/4 transfers
16 — the Forward face cover
17 — Klapanny an emphasis
18 — the Top dividing plate
19 — the Steel ball
20 — the Spring of dumping of pressure
21 — the Intermediate plate
22 — the Nut
23 — the Jet
24 — the Oil filter
25 — the Bottom dividing plate
26 — the Bottom section of klapanny assembly
27 — Reduktsionny the valve
28 — the Spring of the reduktsionny valve
29 — the Adjusting screw
30 — the Face cover

31 — the Valve of management of switching of N/R
32 — the Spring of the valve of switching of N/R
33 — the Spring the valve of management of coupling of the converter of rotation (TCC)
34 — the Valve of management of TCC
35 — the Plug of the valve of management of TCC
36 — the Valve of the face coupling of coupling
37 — the Spring of the valve of the face coupling
38 — the Stopper of the valve of the face coupling
39 — the Emphasis
40 — the Pin
41 — the Directing plug
42 — the Block
43 — the Tube
44 — the Electromagnetic valve of management of pressure (PCSV)
45 — the Electromagnetic valve In managements of switching (SCSV-B)
46 — the Electromagnetic valve A of management of switching (SCSV And)
47 — the Electromagnetic TCC valve
48 — the Valve of switching of 1/2 transfers
49 — the Spring of the valve of switching of 1/2 transfers
50 — the Back face cover
51 — the Valve of management of switching
52 — the Persistent clamp
53 — a valve Stopper In managements of switching
54 — the Plug of the valve of management of N/R switching
55 — the management Valve N/R switching
56 — the Manual valve
57 — the Top section of klapanny assembly
58 — the Teflon ball


 PERFORMANCE ORDER

1. The design of klapanny assembly of transmissions of the F4А20 series is presented on an illustration.
2. Remove manual and electromagnetic valves. Remove a persistent clamp with a collar. Turn out 13 fixing bolts and remove the bottom section of klapanny assembly.

 

3. Remove a dividing plate from the intermediate. Remove a spring of dumping of pressure and take from an intermediate plate two steel balls and the oil filter. Turn out 8 fixing bolts and remove an intermediate plate from the top section of klapanny assembly.
4. Remove from the top section of klapanny assembly three steel balls and one teflon, also remove two lock clamps. Turn out jams and take springs and valves.


Check of a condition of components and assembly

 PERFORMANCE ORDER

1. Carefully wash out all components of assembly in ATF and do not wipe them then rags. Check a condition of working surfaces of valves and the assembly case.
2. Estimate a condition of klapanny springs. Measure height of springs and compare result of measurement to requirements of Specifications. In case of need make replacement.
3. Grease with transmission liquid and establish on the regular places all valves and klapanny springs. Screw and tighten jams. Track, that all fixing bolts were tightened with demanded effort.


Transmission assembly

Before installation all components it is necessary to grease ATF, and sealing rings and epiploons - technical vaseline. Vaseline can be used also for temporary fixing of bearings, persistent holders and washers, - track correctness of orientation of components at installation them on assembly.


F3А21 transmission

 PERFORMANCE ORDER

1. Before installation measure a gap of brake assembly lowered transfers/reverse and, proceeding from results of measurement, pick up press a disk of the corresponding thickness (see further).
2. Establish jet and brake plates of assembly. Establish press a disk of the picked-up thickness. Establish a returnable spring, - track correctness of installation of a spring.

3. Grease with technical vaseline and establish on the regular place on the central emphasis a wavy spring. Place the central emphasis in a casing and establish a lock ring. Having fixed a tsiferblatny measuring instrument of DTI on the back party of a case of transmission, define a gap of brake assembly lowered transfers/reverse, - pass щуп a measuring instrument in an opening under installation of a distributing shaft so that the plunzher appeared is perpendicular to a jet plate of brake assembly.

4. The manual pump pump up air in brake assembly lowered transfers/reverse and consider the indication of a measuring instrument of DTI. By selection of a press disk of the corresponding thickness finish demanded installation of a gap (0.80 ÷ 1.00 mm).

5. Transfer a transmission case on a workbench and lay a surface interfaced to klapanny assembly up. Fill in a case a target flange. Fix a flange a lock ring, having established the last from the outer side of a case. Plant in a case a remote ring of an intermediate gear wheel of distributing assembly.

6. Establish assembly of an intermediate gear wheel of the distributing mechanism with shaft. By means of a special key of MD998344 tighten an intermediate shaft.

7. Fill MD998343 head in a target flange and by means of a dinamometrichesky key measure a torque of a provorachivaniye of a flange. Demanded value makes 0.8 H • m, - in case of need make the corresponding adjustment by pulling up/weakening of effort of a tightening of a shaft.

8. Having finished pretightness adjustment, establish a lock plate of an intermediate shaft. Establish the holder of the bearing, fill in assembly a distributing shaft and establish on it the MD998319 adaptation.

9. By means of the special driver plant the bearing on a distributing shaft, then press in a case an external holder. Establish a conducted gear wheel of a distributing shaft, then plant on a shaft pin a lock ring.

10. Plant on a flange a persistent holder No. 13. Fill in a transmission case the holder of planetary assembly with the persistent bearing No. 12. Establish in the holder of planetary transfer both solar gear wheels.

11. Establish brake assembly lowered transfers/reverse assembled with planted earlier press disk. Establish a returnable spring. Grease with technical vaseline and establish on the central emphasis a wavy spring.

12. Fill in hydraulic openings of the central emphasis two new sealing rings, - before landing grease rings with transmission liquid.

13. Establish assembly of the central emphasis, - track, that sealing rings and a wavy spring did not drop out. Fix assembly by a lock ring.
14. Establish an anchor rod of a tape of brake assembly of the kickdown mode. Having replaced sealing rings, establish servo-driver assembly. Plant new sealing rings from internal and external edges of the coupling of the servo-driver, - pay attention that rings differ from each other in a section form (from internal edge the ring of round section is established, from the external - D-shaped). Fill the coupling in a case of transmission and fix it a lock ring. Establish a brake tape, having attached its edges to an anchor rod and a rod of the piston of the servo-driver.
15. Establish a drum and plant on it a brake tape. Grease with technical vaseline the persistent bearing No. 8 and plant it on a brake drum of the kickdown servo-driver. Also having greased with vaseline, establish a persistent holder No. 7 on a nave of the back coupling of coupling.
16. Plant a nave of the back coupling on a shlitsa of a solar gear wheel of planetary transfer and establish on it outside the persistent bearing No. 6. From the back party of the coupling establish a persistent washer No. 2 and the persistent bearing No. 4. Connect the forward coupling with back and plant assembly in a transmission case. Establish differential.
17. If measured in process of dismantle axial люфт primary shaft fell outside the limits an admissible range, modify it by selection for thickness of a persistent holder No. 3 and a persistent washer No. 1. Demanded value axial люфта makes 0.30 ÷ 1.00 mm.
18. Having replaced sealing laying, plant on the regular place assembly of the oil pump. Screw fixing bolts and tighten them with demanded effort. In summary once again check axial люфт primary shaft.
19. Lay two pieces of tin solder of 10 mm in length and 3 mm in diameter from two parties of an external holder of the bearing of differential. The same slices of solder lay on an interfaced surface of a dome of the converter of rotation around an opening under installation of a distributing shaft. Establish in a dome a bearing holder.

20. Without laying establish a dome of the converter and tighten bolts of its fastening with effort of 19 ÷ 23 H • m.
21. Give bolts, remove a dome and measure thickness flattened out solder slices. Pick up a remote ring of differential according to a formula: thickness of solder plus thickness of sealing laying (0.38 mm), minus size axial люфта differential (0 ÷ 0.15 mm).
22. The thickness of a remote ring of a distributing shaft is defined as follows: Thickness of solder plus thickness of sealing laying (0.38 mm), plus size of a pretightness of the bearing (0.10 ÷ 0.15 mm).
23. Establish in a converter dome the corresponding remote ring of adjustment of a pretightness of the bearing of a distributing shaft.

Rings in a range of thickness from 0.82 mm to 1.69 mm with a step of 0.03 mm are issued. Establish a holder of the bearing of a distributing shaft. Establish the corresponding remote ring on the differential bearing, - rings steal up from a range of thickness 1.31 — 2.13 mm.

24. Grease with silicone greasing the sites of an interfaced surface of a case of transmission equipped with a notch, then establish sealing laying. Establish a converter dome. Screw fixing bolts and tighten them with demanded effort.
25. Fill in a case against the stop an axis of a manual control lever (without a sealing ring). Plant a sealing ring in acting from the outer side of a case a flute. Slightly delay an axis back and screw the adjusting screw.
26. Establish an emphasis of a rasporny rod. Establish three sealing rings маслотоков on klapanny assembly. Grease ATF of a cuff of the piston of the accumulator and plant the piston in a transmission case. Establish on the regular place klapanny assembly and tighten with demanded effort bolts of its fastening.
27. Establish the oil filter. Screw fixing bolts and tighten them with demanded effort. Having replaced sealing laying, establish the case pallet with the magnets enclosed in it. Tighten with demanded effort bolts of fastening of the pallet. Grease with transmission liquid an interfaced surface of the converter and establish on a dome a cover. Measure distance between a cover and a gear wheel end face: adjusting depth should equal approximately 12.0 mm.


F4А20 series transmissions

 PERFORMANCE ORDER

1. Before starting assembly measure size of a gap of brake assembly lowered transfers/reverse and pick up corresponding on thickness press a disk.
2. Establish in a transmission case a jet plate of brake assembly, brake plates and disks, - track for correctness of installation of a press disk. Correctly establish a returnable spring.
3. Grease a wavy spring with technical vaseline and establish it on assembly of the central emphasis. Establish the central emphasis in a case of transmission and fix it a lock ring. By means of a measuring instrument of DTI check size of a gap of brake assembly lowered transfers/reverse. Activation of brake assembly is made by means of the manual pump), - pick up corresponding on thickness press a disk (the size of a gap should not fall outside the limits a range of 1.00 ÷ 1.20 mm).
4. Remove all earlier established components.
5. Establish in a transmission case an external holder of the bearing of a distributing shaft. Plant on a shaft bearings, fill assembly in a case and center it by means of the MD998319 tool.
6. Plant on a pin of a distributing shaft a remote ring of the maximum thickness (1.80 mm). Press on the regular place a conducted gear wheel of a distributing shaft. Having clamped a shaft pin in a vice, tighten its lock-nut with demanded effort (215 H • м).
7. Measure size axial люфта a distributing shaft. the result of measurement should not fall outside the limits an admissible range (0 ÷ 0.025 mm), - pick up a remote ring corresponding on thickness (rings are issued in a range of thickness of 1.82 ÷ 2.13 mm with a step of 0.06 mm). having modified a gap, зачеканьте a lock-nut.
8. Grease an intermediate gear wheel of distributing assembly and press it to AT case. Establish two konusny roller bearings, fill assembly of an intermediate gear wheel with bearings in a case and pass in it outside a shaft.
9. Tighten a shaft of an intermediate gear wheel by means of the MD998344 tool. Fill MD998906 head in a target flange and by means of a dinamometrichesky key measure a torque of a provorachivaniye of a flange. Demanded value makes 0.8 H • m, - in case of need make the corresponding adjustment by pulling up/weakening of effort of a tightening of a shaft.
10. Having finished pretightness adjustment, establish a lock plate of an intermediate shaft. Establish the holder of the bearing, screw new screws and tighten them with demanded effort.
11. Plant in a transmission case the holder of planetary assembly with the persistent bearing No. 12. Establish on a solar gear wheel of forward transfers the persistent bearing No. 9 and a holder No. 10. Operating in a similar manner, collect a solar gear wheel of a reverse gear and establish it in the holder.
12. Establish brake assembly lowered transfers/reverse assembled with picked-up and planted earlier press disk. Establish a returnable spring. Grease with technical vaseline and establish on the central emphasis a wavy spring. Fill in hydraulic openings of the central emphasis two new sealing rings, - before landing grease rings with transmission liquid.
13. Establish assembly of the central emphasis, - track, that sealing rings and a wavy spring did not drop out. Fix assembly by a lock ring, having tracked, that the lock of the last did not appear developed towards a fixing opening of the pulse generator A.
14. Establish an anchor rod of a tape of brake assembly of the kickdown mode. Plant on the servo-driver piston new sealing rings, - pay attention that rings differ from each other on diameter and a section form. Plant a new sealing ring in a flute on the coupling. Fill in a transmission case a spring, the piston and the coupling of the servo-driver and fix assembly by a lock ring. Establish a brake tape, having attached its edges to an anchor rod and a rod of the piston of the servo-driver.
15. Establish a drum and plant on it a brake tape. Grease with technical vaseline the persistent bearing No. 8 and plant it on a brake drum of the kickdown servo-driver. Also having greased with vaseline, establish a persistent holder No. 7 on a nave of the back coupling of coupling.
16. Plant a nave of the back coupling on a shlitsa of a solar gear wheel of planetary transfer and establish on it outside the persistent bearing No. 6. From the back party of the coupling establish a persistent washer No. 2 and the persistent bearing No. 4. Connect the forward coupling with back and plant assembly in a transmission case. Establish differential.
17. If measured in process of dismantle axial люфт primary shaft fell outside the limits an admissible range, modify it by selection for thickness of a persistent holder No. 3 and a persistent washer No. 1. Demanded value axial люфта makes 0.30 ÷ 1.00 mm.
18. Having replaced sealing laying, plant on the regular place assembly of the oil pump. Screw fixing bolts and tighten them with demanded effort. In summary once again check axial люфт primary shaft.
19. Lay two pieces of tin solder of 10 mm in length and 3 mm in diameter from two parties of an external holder of the bearing of differential. Without laying establish a dome of the converter and tighten bolts of its fastening with effort of 19 ÷ 23 H • m.
20. Give bolts, remove a dome and measure thickness flattened out solder slices. Pick up a remote ring of differential according to a formula: thickness of solder plus thickness of sealing laying (0.38 mm), minus size axial люфта differential (0 ÷ 0.15 mm).
21. Establish the corresponding remote ring on the differential bearing, - rings steal up from a range of thickness of 1.85 ÷ 65.28 mm with a step of 0.09 mm.
22. Grease with silicone greasing the sites of an interfaced surface of a case of transmission equipped with a notch, then establish sealing laying. Press to transmission a converter dome. Screw fixing bolts and tighten them with demanded effort.
23. Establish a shaft of the face coupling of coupling (the long, equipped shlitsa a pin towards the converter) for the end of a returnable spring of the coupling plant a persistent washer.
24. By supply of air in the corresponding unions check serviceability of functioning of couplings of coupling.

The zakachivaniye in transmission only absolutely dry air is allowed! Do not lift pressure in transmission above what to 1.75 kgfs/cm2.

25. Fill in a case against the stop an axis of a manual control lever (without a sealing ring). Plant a sealing ring in acting from the outer side of a case a flute. Slightly delay an axis back and screw the adjusting screw. Establish a ball and a clamp spring.
26. Establish an emphasis of a rasporny rod. Grease ATF of a cuff of the piston of the accumulator and plant the piston in a transmission case. Establish a sealing ring маслотока brake assembly from above in the central part of klapanny assembly and plant the last on the regular place. Screw and tighten with demanded effort fixing bolts.
27. Establish the oil filter. Screw fixing bolts and tighten them with demanded effort. Having replaced sealing laying, establish the case pallet with the magnets enclosed in it. Tighten with demanded effort bolts of fastening of the pallet. Having replaced a sealing ring, establish on the regular place the sensor switch of the servo-driver of the kickdown mode and fix it a lock ring. Establish the PNP sensor switch and a manual control lever.
28. Adjust the sensor switch of permission of start (PNP). Establish pulse generators A and V.Smazhte transmission liquid an interfaced surface of the converter and establish on a dome a cover. Measure distance between a cover and a gear wheel end face: adjusting depth should equal approximately 12.0 mm.