Assembling Overdrive

NOTE: Use new gaskets, O-rings and seals when assembling overdrive. Observe utmost cleanliness since the hydraulic system is very sensitive to dirt.

Assembling Rear Housing





1. Press bearing in rear housing. Use drift P/N 2412.





2. Press on bearing on output shaft. Use drift P/N 2412.





3. Install spacer sleeve on output shaft. (On Type J: speedometer drive gear.)





4. Press output shaft in rear housing. Use drift P/N 2412.





5. Tap oil seal into rear housing. Use drift P/N 5308.

NOTE: Type P: Proceed to operation 13.Operations G6 to 12 only refer to Type J.

6. Before installing one-way clutch:
- Make sure thrust washer is correctly positioned.
- If thrust washer is replaced, make sure that it is correctly positioned. It should be 0.6 mm (0.024 in) above edge.





7. Correct thrust washers:
- Use thickness 2.5 mm (0.1 in), P/N 380 715-3, for early version of output shaft, P/N 380 679-1 and P/N 1 232 105-5.
- Use thickness 3.8 mm (0.15 in), P/N 1 232 644-4, for output shaft P/N 1 232 646-3.





8. Install one-way clutch hub and roller cage with rollers.





9. Install oil slinger and lock ring. Check that one-way clutch functions correctly.





10. Install drive flange. Apply locking fluid, P/N 1161 075-5, to splines. Be careful not to apply to seal. Use press tool P/N 1845 if required.

11. Install nut. Torque to 175 Nm (130 ft lb.).
- Round drive flange: use wrench P/N 5149.
- Three-arm drive flange: clamp drive flange in a vice.





12. Install planetary gear on output shaft. Guide splines into carrier and one-way clutch hub. Use centering drift P/N 2835.

NOTE: Proceed to operation 18. Operations 13 to 17 only apply to Type P.





13. Install drive flange. Apply locking compound, P/N 1161 075-5, to splines. Be careful not to apply to seal. Use press tool P/N 1845 if required.
14. Install nut. Torque to 175 Nm (130 ft lb).
- Round drive flange: use wrench P/N 5149.
- Three-arm drive flange: clamp drive flange in a vice.





15. Position roller cage for one-way clutch. Groove on roller cage should face UP. Use a drift to tap in oil slinger.





16. Press one-way clutch hub on to planetary gear carrier.
- Wipe off splines.
- Bevelled edge on hub should face DOWN.
- Use ring 5210 when pressing.





17. Install brass thrust washer and planetary gear carrier.

Installing Clutch Assembly

2806 Drift:

18. Press in bearing. Use drift P/N 2806. Attach lock ring.

NOTE: Type P: Proceed to operation 21. Operations 19 to 21 only apply to Type J.





19. Asbestos-free clutch linings in overdrive Type J for D24 T. From transmission serial number 1 208 438/107 770, the D24 T is equipped with asbestos-free linings in the overdrive. However, there are some D 24 T models with higher transmission serial numbers which have the old type friction linings, see below.





NOTE: The asbestos-free material has improved friction properties, which make it possible to reduce overdrive oil pressure to 2.8-3.1 MPa (400-440 psi). The new clutch linings also have a larger area.





20. When overhauling.
- For Turbo vehicles, clutch linings of the asbestos-free type (P/N 1 377039-1) should be used, unless already used as shown in chart above.
- When replacing clutch linings, the brake drum should also be replaced. P/N 380910-0.

NOTE: All Type P overdrives have asbestos-free clutch linings.





21. Dry clutch in a warm place. All moisture must be removed from the friction lining before the clutch is fitted to the front housing. When dry, oil lining with ATF type F or G.
22. Install sun gear, clutch and lock rings.





23. Install:
- clutch assembly.
- springs.
- gasket between rear housing and brake drum. Make sure gasket is installed correctly.
- brake drum.





Assembling Front Housing
Prior to assembling, make sure front housing is carefully cleaned. The hydraulic system is very sensitive to dirt

24. Lubricate oil pump with ATF before fitting to front housing. Make sure that the groove and bevel on the pump plunger are aligned with the recess for the pressure filter. This prevents knocking noise from pump.

25. Check non return valve seat for leakage.
Blow through the valve to check for leakage. If the leakage is slight place the seat and steel ball on a flat surface and tap the ball with a plastic mallet. Recheck.

If the leakage is large the valve seat is probably too oval and therefore should be replaced. Make sure when fitting the valve that the steel ball is positioned correctly.





26. Install:
1. Oil filter, gasket and plug.
2. Seat, ball, spring and plug for check valve. Make sure ball is positioned correctly.
3. Relief valve parts. Always use new type if piston is replaced. Install shims, if applicable.

NOTE: If new clutch linings of asbestos-free type have been installed, no shims should be fitted to the relief valve.





27. Torque plugs using plug wrench P/N 2836 and torque to 22 Nm (16 ft lb).





28. Install oil pan, strainer and gasket. Make sure magnet in oil pan is cleaned. Torque bolts to 10 Nm (7 ft lb).
29. Position clutch pistons in cylinders.

NOTE: As a running modification during the Spring of 1985, 4 mm longer clutch pistons with a Teflon ring on the outside of the O-ring for improved sealing, have been installed. Pistons with 0-rings should be replaced by new type pistons with Teflon ring, P/N 1 377 041-7.





29. Assemble rear and front housings.

NOTE: Make sure gasket fitted between brake drum and rear housing is installed.

Remove remains of old nylon washers from two upper bolts on rear housing. Install new nylon washers, small end towards rear housing. Torque nuts in stages to 12 Nm (9 ft ft lb).
30. Install bridges. Torque nuts to 10 Nm (7 ft lb).





31. Install solenoid. Attach ground wire. Use crow-foot wrench P/N 5172. Torque to 50 Nm (37 ft lb).