Overhaul - 4L30-E: Other BMW 3 series E36

ELECTRICAL COMPONENTS

For servicing of electrical components, see AUTOMATIC TRANSMISSIONS DIAGNOSIS article.

PRELIMINARY PROCEDURE

1. Before performing transmission trouble shooting, check fluid level, fluid condition and shift linkage adjustment. Check for proper control module application in relation to transmission part number.
2. Perform hydraulic pressure test to identify problem. See «HYDRAULIC PRESSURE TEST»(ref-57009-S09378590082001011700000) under TRANSMISSION TESTING.

Delayed Gear Engagement In "D" & "R" Positions

1. Defective Teflon Seal Rings On Turbine Shaft
2. Low Line Pressure

Delayed Gear Engagement In "R" Position Only

1. Defective Main Valve Body-To-Transmission Case Gasket
2. Low Line Pressure
3. Missing Check Balls In Valve Body
4. Restricted Orifice At Transfer Plate And Valve Body

Engine Flare During 1-2 Or 2-3 Shift

1. Defective Band Apply Solenoid
2. Defective Or Stuck 1-2 Accumulator Valve
3. Defective Servo Piston Or Seal Ring
4. Low Line Pressure

Engine Will Not Start With Shift Lever In "P" Or "N" Position

1. Defective Mode Switch Or Wiring Circuit
2. Defective Or Improperly Adjusted Mode Switch
3. Improper Shift Linkage Adjustment

Harsh Or Soft Shifts In All Gears

1. Defective Accumulator Piston Or Servo
2. Defective Band Apply Solenoid
3. Defective Clutch Plates Or Brake Band
4. Defective Or Missing Check Ball In 2nd And 3rd Clutch Pistons
5. Defective Seal Rings
6. Excessive Clutch Piston Travel
7. Improper Line Pressure

Harsh Shift Into "D" Position Or Accelerating From A Stop

1. Defective Band Apply Solenoid
2. Excessive Line Pressure

Harsh 1-2 Shift

1. Defective Or Stuck 1-2 Accumulator Valve
2. Excessive Line Pressure

Harsh 3-4 Shift

1. Defective Or Stuck 3-4 Accumulator Piston
2. Defective Or Stuck 3-4 Accumulator Valve
3. Excessive Line Pressure

Improper 3-2 Shift

1. Defective Band Apply Solenoid
2. Low Line Pressure

Intermittent 4-2 Downshift At Steady Speed

1. Defective Mode Switch Or Wiring
2. Defective Transmission Speed Sensor Or Wiring

No Engine Braking

1. Damaged Piston Seal Ring On Overrun Clutch Piston
2. Defective Or Stuck Overrun Lock-Out Valve On Center Support
3. Defective Teflon Seal Rings On Turbine Shaft
4. Defective Turbine Shaft
5. Defective 3-4 Accumulator Piston
6. Excessive Overrun Clutch Piston Travel
7. Low Line Pressure

No Forward Or Reverse Gears

1. Defective Overdrive One-Way Clutch
2. Defective Shift Linkage
3. Defective Turbine Shaft
4. Low Line Pressure

No 1st & 2nd Gears, Or No 3rd & 4th Gears

1. Defective Shift Solenoid

No 3rd Or 4th Gears

1. Defective Shift Solenoid

No 1st & 4th Gears, Or No 2nd & 3rd Gears

1. Defective Shift 1-2/3-4 Shift Solenoid

Vehicle Will Not Move In 3rd gear In Winter Mode

1. Defective Accumulator Piston
2. Defective Or Missing Check Ball In 2nd Clutch Piston
3. Defective 2nd Clutch Seals
4. Excessive 2nd Clutch Piston Travel
5. Internal Hydraulic Pressure Leakage

For servicing of electrical components, see AUTOMATIC TRANSMISSIONS DIAGNOSIS article.

TRANSMISSION

See TRANSMISSION REMOVAL & INSTALLATION - A/T article in the TRANSMISSION SERVICING section.

MAIN VALVE BODY

ADAPTER CASE VALVE BODY

VALVE BODIES & INTERNAL COMPONENTS

Note. Lubricate all components with Dexron-III ATF before reassembly. Coat all thrust bearings assemblies with petroleum jelly before installing.

Scheme 31

Scheme 32

Scheme 33

Scheme 34

1. Install NEW shaft seal for selector shaft in transmission case. Install selector shaft. Install spring pin in transmission case. see scheme 9 DO NOT install spring flush with surface on transmission case.
2. Install parking lock and range selector lever with actuator rod on selector shaft. Install and tighten selector shaft nut to specification. See «TORQUE SPECIFICATIONS»(ref-57009-S00687949562001011700000).
3. Install brake band in transmission case. Ensure servo pin area aligns with servo hole. Install thrust bearing assembly in rear of transmission case.
4. Install brake drum, reaction sun gear and needle bearing. see scheme 8 Install thrust bearing assembly on output shaft on planetary carrier.
5. Pinions on planetary carrier must be properly aligned. Each pinion is marked with 2 dots to indicate master tooth space and a single dot to indicate the master tooth. Planetary carrier is marked with double lines which should align with the 2 dots on 2 opposite pinions. Single lines on planetary carrier should align with single dot on the other 2 pinions. (Scheme 31)
6. Properly align all pinion on planetary carrier. Install 2nd and 3rd clutch assemblies on planetary carrier. If pinions are properly aligned, 2nd and 3rd clutch assembly should fit easily on planetary carrier.
7. Rotate 3rd clutch and ensure pinions with 2 dots are at tooth No. 1 and 46 on ring gear in 2nd clutch assembly. (Scheme 31) Pinions with one dot should be between tooth No. 23 and 24 on ring gear in 2nd clutch assembly. If not as specified, realign as necessary.
8. Once correct pinion alignment is obtained, install planetary carrier in transmission case. Install washer and bearing on planetary carrier. see scheme 8
9. Install thrust washer on 2nd clutch. Ensure tangs on thrust washer engage with slots on second clutch. Align tangs on clutch plates in 2nd clutch. Install 3rd clutch assembly in 2nd clutch drum.
10. Install assembled 2nd and 3rd clutch assemblies in transmission case. Ensure planetary carrier is properly aligned. Rotate output shaft and clutch assemblies to ensure proper engagement.
11. Install pressure plate in transmission case. Ensure pressure plate is installed in proper direction with lip side facing upward. see scheme 8 Tang side on pressure plate must be toward main valve body surface on transmission case.
12. Install reverse clutch plates and clutch discs, starting with clutch plate and alternating with clutch disc. Install waved plate with center tang facing valve body surface on transmission case.
13. The 2nd clutch end play must now be checked. Install Selective Thrust Washer Gauge (J-23085-A) on transmission case, against intermediate shaft. Move inner shaft on selective thrust washer gauge downward against thrust surface on 2nd clutch hub. Perform STEP 1. (Scheme 32) Tighten thumb screw on selective thrust washer gauge.
14. Remove selective thrust washer gauge from transmission case. Install spacer ring on inner shaft of selective thrust washer gauge. Measure distance "G" from end of inner shaft to surface on spacer ring. Perform STEP 2. (Scheme 32)
15. Using dimension "G", determine color code of selective thrust washer that fits on the center support. See «SELECTIVE THRUST WASHER SPECIFICATIONS»(ref-57009-S14990253952001011700000) table. This should provide a final 2nd clutch end play of.014-.031" (.36-.79 mm). SELECTIVE THRUST WASHER SPECIFICATIONS Dimension "G": In. (mm) Color Code.060-.064 (1.53-1.63) Yellow.068-.072 (1.72-1.82) Red.075-.079 (1.91-2.01) Black.083-.087 (2.10-2.20) Natural.090-.094 (2.29-2.39) Green.098-.102 (2.48-2.58) Blue
16. Install NEW seal rings on 4th clutch piston. Lubricate seal rings with Dexron-III ATF. Install 4th clutch piston in adapter case. Use care not to damage seal rings.
17. Install 4th clutch retainer and spring assembly on 4th clutch piston. see scheme 8 Using spring compressor, compress 4th clutch spring retainer and spring assembly. Install snap ring in adapter case. Remove spring compressor.
18. Apply petroleum jelly on selective thrust washer. Install selective thrust washer on center support. Install NEW "O" rings on front of transmission case and NEW seal ring on adapter case. see scheme 8
19. Install guide pins in front of transmission case for aligning adapter case. Install adapter case and center support assembly on transmission case.
20. Install thrust washer on adapter case. Ensure tangs on thrust washer engage with slots in adapter case. Apply petroleum jelly on thrust bearing and install at center of overdrive internal gear with Black side of thrust bearing facing upward. see scheme 7
21. Install overdrive internal gear with thrust bearing on turbine shaft and overrun clutch assembly. Install turbine shaft and overrun clutch assembly with overdrive internal gear in adapter case.
22. Install 4th clutch plates and clutch discs in following order: clutch plate, clutch disc, clutch plate, clutch plate, clutch disc and clutch plate. Clutch plates must be installed with short tang facing toward adapter case valve body surface.
23. Install 4th clutch retainer with notch area toward adapter case valve body surface. Overdrive clutch end play must now be checked.
24. Install Selective Thrust Washer Gauge (J-23085-A) on adapter case, against turbine shaft. Move inner shaft on selective thrust washer gauge downward against thrust surface on overrun clutch housing. Perform STEP 1. (Scheme 33) Tighten thumb screw on selective thrust washer gauge.
25. Remove selective thrust washer gauge from adapter case. Measure distance "G" from end of inner shaft to surface on selective thrust washer gauge. Perform STEP 2. (Scheme 33)
26. Using dimension "G", determine color code of selective thrust washer that fits on rear of oil pump assembly. See the «SELECTIVE THRUST WASHER SPECIFICATIONS»(ref-57009-S14990253952001011700000) table. This should provide a final overdrive clutch end play of.004-.031" (.10-.80 mm).
27. Install NEW outer seal ring on torque converter housing and NEW gasket on oil pump assembly. see scheme 11 Apply petroleum jelly on selective thrust and install on rear of oil pump assembly. Ensure selective thrust washer is fully seated on oil pump assembly.
28. Install torque converter housing with oil pump assembly on adapter case. Install and tighten torque converter housing-to-adapter case bolts to specification. Ensure oil pump gears rotate freely.
29. Install dial indicator, Turbine Shaft Puller (J-25022) and End Play Fixture (J-24773-1) onto turbine shaft. (Scheme 34) Pull turbine shaft upward until slight resistance is felt. Zero dial indicator.
30. Continue to pull turbine shaft upward and note turbine shaft end play. Turbine shaft end play should be.004-.031" (.10-.80 mm). Remove dial indicator, turbine shaft puller and end play fixture.
31. If turbine shaft end play is not within specification, different thickness selective thrust washer must be installed on rear of oil pump assembly. Repeat steps 24) through 26) for selective thrust washer selection procedure.
32. On 2WD models, install NEW bearing in extension housing if replacement is required. On all models, install NEW oil seal in extension housing. Install NEW seal ring on parking lock gear if seal ring is damaged. see scheme 5
33. Install parking lock gear, speed sensor drive gear and retaining ring on output shaft. see scheme 5 Using NEW gasket, install extension housing. Ensure parking pawl shaft and actuator rod are aligned with extension housing. Install and tighten extension housing bolts to specification.
34. On 2WD models, install drive shaft companion flange and NEW "O" ring on output shaft. Install and tighten drive shaft companion flange nut to specification.
35. On all models, using a NEW "O" ring, install speed sensor. Install and tighten bolt to specification. Position transmission with output shaft facing upward. Install dial indicator on extension housing with stem of dial indicator against output shaft. Zero dial indicator.
36. Manually push output shaft upward and note output shaft end play. Output shaft end play should be.014-.031" (.36-.80 mm). If output shaft end play is not within specification, different thickness selective thrust washer must be installed on center support. Repeat steps 13) through 15) for selective thrust washer selection procedure.
37. Ensure brake band is correctly positioned, rotate output shaft if necessary. Install NEW seal ring on servo piston if necessary. Install apply rod in transmission case with rounded end of rod toward the brake band.
38. Install return spring and servo piston. Use care not to damage seal ring on servo piston. Using spring compressor, compress servo piston and return spring. Install servo piston retaining snap ring. Remove spring compressor.
39. To adjust brake band, loosen lock nut on servo adjusting screw. see scheme 5 Using an INCH-lb. torque wrench, tighten servo adjusting screw to 40 INCH lbs. (4.5 N.m).
40. Back off servo adjusting screw 5 revolutions. Hold sleeve on servo piston. Tighten lock nut to 14 ft. lbs. (19 N.m). Ensure servo adjusting screw does not rotate while tightening lock nut.
41. Install 2 check balls in transmission case. see scheme 6 Install case 4-pin connector and wiring harness. Install guide pins for main valve body in transmission case.
42. Install assembled main valve body and manual valve link assembly. Manual valve link must be extended, as long end fits into manual valve and short end fits into range selector. Remove guide pins. Install and tighten main valve body bolts to specification. Install electrical connectors at solenoids on main valve body.
43. Using a NEW gasket, install servo cover. Install and tighten bolts to specification. Install manual detent on main valve body. see scheme 5 Install and tighten bolts to specification.
44. Install a NEW oil filter. Install and tighten bolts to specification. Using NEW gasket, install main case oil pan. Install and tighten bolts to specification.
45. Install 5-pin electrical connector in adapter case. Using NEW transfer plate gaskets, install adapter case valve body and transfer plate. Install and tighten bolts to specification. Install electrical connectors at solenoids on adapter case valve body.
46. Using a NEW gasket, install adapter case oil pan. Install and tighten bolts to specification. Using a NEW seal ring, install oil filler tube. Install and tighten bolt to specification.
47. Install and adjust mode switch. For mode switch adjustment, see «AUTOMATIC TRANSMISSIONS DIAGNOSIS»(ref-57011) article. Install NEW "O" ring on end of turbine shaft. Install torque converter.