Automatic gearbox 099 - 4-speed

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Location on gearbox
  1
• 1.2 Code letters and date of manufacture of gearbox arrow 1
  1
• 2 Notes on automatic gearbox 099
  2
• 2.1 Notes on automatic gearbox 099
  2
• 3 Code letters, engine allocation, ratios, equipment
  3
• 4 Capacities
  8
• 4.1 Planetary gear
  8
• 4.2 Final drive
  8
• 5 Repair instructions
  9
• 5.1 Repair instructions
  9
• Torque converter
  12
• 1 Torque converter
  12
• 1.1 Identification of torque converter
  12
• 1.2 Allocation of torque converter
  12
• 1.3 Removing and installing torque converter oil seal
  15
• 1.4 Draining torque converter
  15
• Controls, housing
  17
• 1 Electrical and electronic components and their locations
  17
• 2 Repairing selector mechanism for vehicles before 05.00
  23
• 2.1 Checking selector mechanism
  23
• 2.2 Checking and adjusting selector lever cable
  24
• 2.3 Dismantling and assembling selector mechanism
  24
• 2.4 Removing and installing selector lever cable
  25
• 2.5 Dismantling and assembling selector lever
  29
• 2.6 Adjusting starter inhibitor switch in right-hand drive vehicles
  31
• 3 Repairing selector mechanism for vehicles after 06.00
  32
• 3.1 Checking selector mechanism
  32
• 3.2 Checking and adjusting selector lever cable
  33
• 3.3 Checking operation of the ignition key withdrawal lock
  35
• 3.4 Removing and installing selector lever handle
  36
• 3.5 Removing and installing selector mechanism
  38
• 3.6 Dismantling and assembling selector mechanism on vehicles before 06.01
  40
• 3.7 Dismantling and assembling selector mechanism on vehicles after 07.01
  42
• 3.10 Removing and installing pull rod top part
  48
• 3.11 Removing and installing selector lever cable
  49
• 3.12 Removing and installing locking cable
  53
• 3.13 Adjusting locking cable in vehicles before 06.01
  58
• 3.14 Adjusting locking cable in vehicles after 07.01
  59
• 4 Checking gearbox
  60
• 4.1 Connecting vehicle diagnosis, testing and information system VAS 5051
  60
• 4.2 Checking shift points
  60
• 4.3 Checking stall speed
  60
• 4.4 Fault finding table for “4-speed automatic gearbox”
  61
• 4.5 Repair of “4-speed automatic gearbox” with an exchange component
  61
• 4.6 Measuring main pressure
  61
• 5 Removing and installing gearbox
  65
• 5.1 Removing and installing gearbox for vehicles before 05.00
  65
• 5.2 Removing and installing gearbox for vehicles after 06.00
  73
• 6 Checking ATF level and topping up
  82
• 6.1 Checking ATF level
  83
• 6.2 Topping up ATF
  85
• 6.3 Renewing ATF
  86
• 7 Gearbox with selector elements
  87
• 8 Dismantling and assembling gearbox
  90
• 8.1 Removing and installing ATF cooler and ATF filler pipe
  90
• 8.2 Dismantling and assembling planetary gearbox -Overview-
  90
• 8.3 I - Removing and installing ATF pump to supporting tube
  91
• 8.4 II - Removing and installing reverse clutch -K2- to large sun gear
  93
• 8.5 III - Removing and installing freewheel and reverse gear brake -B1-
  94
• 8.6 IV - Planet carrier and gearbox housing with input gear and cover
  95
• 8.7 Dismantling and assembling planetary gearbox
  97
• 8.8 Overview of all planetary gearbox adjustments
  110
• 8.9 Adjusting planet carrier
  112
• 8.10 Adjusting reverse gear brake -B1-
  116
• 8.11 Adjusting clutch play between -K1- and -K2-
  119
• 8.12 Adjusting 2nd and 4th gear brake -B2-
  122
• Gears, control
  131
• 1 Dismantling and assembling ATF pump
  131
• 2 Dismantling and assembling freewheel with -B1- piston
  133
• 3 Dismantling and assembling 1st to 3rd gear clutch -K1-
  135
• 4 Dismantling and assembling reverse gear clutch -K2-
  138
• 5 Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft
  141
• 6 Removing and installing valve body
  144
• 7 Dismantling and assembling parking lock
  149
• Final drive - differential
  154
• 1 Checking oil in final drive
  154
• 2 Removing and installing oil seal for stub shaft or flange shaft
  155
• 2.1 When renewing oil seal on left
  155
• 2.2 When renewing oil seal on right
  157
• 3 Dismantling and assembling final drive
  160
• 3.1 Repair overview of final drive
  160
• 3.2 Removing and installing bearing housing
  161
• 3.3 Removing and installing input gear
  166
• 3.4 Removing and installing drive shaft
  169
• 3.5 Removing and installing differential
  179
• 3.6 Dismantling and assembling differential
  184
• 4 Adjusting final drive
  193
• 4.1 Overview of adjustments
  193
• 4.2 Adjustments to be completed after replacing individual components
  193
• 4.3 Adjusting drive shaft
  194
• 4.4 Adjusting input gear
  197
• 4.5 Adjusting differential
  198
• 5 Definitions
  205