The B, D & E clutches use the same friction and steel plates. There are 6 frictions in the B-clutch, 5 in the E-brake but the D-brake either has 4 plates (‘029’ model for the 4.4i) or 5 plates (‘034’ model for the 4.6iS). The kit therefore contains a total of 16 plates but you only use 15 of them for the 4.4i

I measure the front and rear endfloat with a DTI :

http://i260.photobucket.com/albums/i...8/EndFloat.jpg

because the tolerance stack-up is a little involved :

http://i260.photobucket.com/albums/i...nceStackUp.jpg

http://i260.photobucket.com/albums/i...ngEndFloat.jpg

If you’ve renewed the bearings then the endfloat is unlikely to have changed from when the transmission was new so the chances are that it is correct with the existing selective washer race.

Phil

Florin,

Phil beat me to it. I am in nicaragua for a few days and didn't see your post.

In my thread I asked the exact same question because i was also stumped at having a disk left over. For the 4.4 there is one disk left over. :-)

LV

The towers are in but... sure I had to run into another problem. The oil pipes don't stay in anymore. I remember Phil mentioned that he always changes them. I thought I could reuse mine but no luck. I have to order them today and wait another week to get them... I am so happy I work on a spare tranny and not mine.
Thanks again guys,
Florin

http://i695.photobucket.com/albums/v...21866-orig.jpg

http://i695.photobucket.com/albums/v...21E6C-orig.jpg

http://i695.photobucket.com/albums/v...28BD9-orig.jpg

Tempting to try reusing but I think they deform too much when removed and reinserting them wont be effective As you already described.

How did you get your hands on a spare tansmission?

Although I thought that the output bearing is good I decided to replace it. It feels something not right sometimes in a certain position when I spin it. The ZF part is about $100 but I can find it locally for $39 FAG brand. The number on it is 6209c3 INA. What is the difference? Should I get the ZF or FAG is good enough.
Louis, I know you mentioned that from the beginning but I like to spend money on shipping :)

INA & FAG are part of the same company (Schaeffler Group) so consider them interchangeable. The C3 designation means that this 85x45x19 deep-groove ball bearing has a larger than normal internal clearance so you need to ensure that its replacement is also a 'C3' type.

Phil

I got an FAG from Eriksson, works fine. Price was about 40 bucks I think.

OK will get the FAG then.
A few check points:

The intermediate plate has a gap of about 0.5mm or so. Is this acceptable? Should I go ahead and torque the bolts?
Before I placed the intermediate plate on the housing I checked Cylinder AB to the transmission housing’s sealing area: 20.5-7mm vs approx. 20mm from the manual which explains the gap I find.
http://i695.photobucket.com/albums/v...-23-03_397.jpg

http://i695.photobucket.com/albums/v...-24-01_848.jpg

The second check point:
The two sealing bushes 01.350 between the transmission housing and cylinder DE. How do I know when they are all the way in? After I pressed the sealing bushes in I measured the depth from the top of the busing to the transmission housing which is about 22mm. Does it mean that they are all the way in?

http://i695.photobucket.com/albums/v...-36-44_318.jpg

No, there's something wrong there. There shouldn't be a gap between the intermediate (oil pump) housing and the main casing - rather than getting endfloat you're going to get interference if you tighten down the bolts, which will result in you crushing the axial bearings. RDM08 asked me exactly the same question when he rebuilt his transmission so I'll refer you back to my previous response : http://www.xoutpost.com/830289-post67.html

I can measure the depth of the sealing sleeves tomorrow if you like - I normally just tap them in using a 3/8" square drive extension bar until they seat. Although they're a bit bouncy (being made of rubber) they should be hard enough to be able to tell when they're fully seated. You don't need to worry that you're inserting them too far because they seal on their end face so they just stop.

Phil

Thanks Phil. I read that before I put everything together. That was a good tip you added in there. I probably would have missed it.
I took the intermediate housing and I found the bearing shim 02.260 was misaligned. Most likely it fell when I put the intermediate housing on the transmission housing and I didn't noticed. I didn't use grease, I just soaked it in oil.

I did the same thing with the sealing sleeves but I wasn't sure made it all the way in the E/D housing bores.

I am waiting for the oil tubes to come... I forgot to order the magnets, This tranny didn't come with magnets on the oil pan. I will destroy some old computer hdd and get the magnets from there.