AW7x Rebuild PDF

Section 4 (43)
Service Manual
Reconditioning
Reconditioning
automatic
transmission
AW70/70L
AW71171 L
AW72L
700, 1982-19 ..
TP 31635/1
Volvo Cars North America
AW 70l AW 711AW 72 L Automatic transmissions

Contents
Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
3
Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Pre-d ismantling instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
Dismantling into main components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Gearbox, dismantling of components

Overdrive unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Clutch CO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Input shaft, planet carrier and freewheel FO . . . . . . . . . . . . . . . . . . . . . ..
Overdrive housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front clutch C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear clutch C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Centre support unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Planetary drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Brake pistons B3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pump. . ... .. ... . . . ......... .. .. . .. .. . ... . .. ... .. ..... . ..... .
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Rear extension housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
24
26
27
28
30
32
34
38
42
43
45
47
General assembly instructions . ... ......... ... . '''. ' . . . . . . . . . . . . ..
47
Gearbox, assembly of components

Clutch CO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input shaft, planet carrier and freewheel FO. . . . . . . . . . . . . . . . . . . . . ..
Overdrive housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Front clutch C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Rear clutch C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Centre support unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Planetary drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pump.. . ........ .. .. .. . .. . . . . .. ... . .. .. .. . . . .. ...... ... . .. .
Brake pistons B3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear extension housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
50
52
56
59
61
65
70
73
74
75
Gearbox, complete reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
Control system, general. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
92
Control system, dismantling into main components . . . . . . . . . . . . . .
95
Control system, dismantling of components

Upper front valve body (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Upper rear valve body (B) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 101
Lower valve body (C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
AW70lAW711AW72L Automatic transmissions

Contents
Page
Cleaning and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 110
General assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 112
Control system, assembly of components
Upper front valve body (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Upper rear valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Lower valve body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 119
Control system, complete reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Control system, assembly of other components. . . . . . . . . . . . . . . . .. 129
Fold-out 1
Gearbox - component names and locations . . . . . . . . . . . . . . . . . . . . . . .. 131
Fold-out 2
Upper and lower valve bodies - component locations. . . . . . . . . . . . . . . . 133
Fold-out 3
Lower valve body (top) - component locations .... . .... . . . .. .... ... . 135
Storage tray 5231 - component locations ... .... ... .. . . . . .. . .. . .. .. . 136
Index, page 137

This manual deals only with reconditioning of the transmission unit itself. See separate manuals regarding
work on the transmission in the car, as well as its removal and installation.
Order No. TP 31635/1
We reserve the right to make alterations without prior notification.
AW 70/AW 71/AW 72 L Automatic transmissions

Contents/identification of transmission
Specifications
Contents
Page
Identification of transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Clearances .......... . . ..... ... .. .... .. .. ...... . .... : . . . . . . . . . .. 5
Transmission fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
Transmission by model year and engine type. . . . . . . . . . . . . . . . . . . . . .. 5
Kickdown cable, torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clutch and brake friction plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Valve spring specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Accumulator pistons, accumulator springs . . . . . . . . . . . . . . . . . . . . . . . . . 9
Replacement schedule - hydraulic control system . ... . .. . . . . . . . . . . . 10
Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
Identification of transmission
148395
This manual deals with reconditioning of the following automatic transmissions installed in models from 1982 on:
AW70
AW 70 L (L indicates that unit is equipped with lock-up function)
AW71
AW 71 L (L indicates that unit is equipped with lock-up function)
AW 72 L (AW 72 is available only with lock-up function)
The transmission is identified from the product plate on the left-hand side of the unit.
3
I.
AW 70/AW 71/AW 72 L Automatic transmissions

Contents/identification of transmission
Identification
The product plate on the unit specifies:

1.
2.
3.
4.
5.
Type designation
Volvo part number
Year and month of manufacture
Serial number (four-digit)
Figure 8 indicates that transmission has been manufactured for Volvo
6. Transmission type code
Example:
72L
- AW72L
1208638 - Volvo part number (as from 1983)

88
- Manufactured in 1988
H
- Manufactured in August (A = January, B =
February .... M = December. I is not used)
P
-AW72L(C=AW 70,K=AW 70L, F = AW71
and H = AW 71 L)
8
- Transmission manufactured for Volvo
1490
- Aisin-Warner serial number (commences with
0001 each month)
88
1490
AW 70lAW 711AW 72 L Automatic transmissions

Specifications
Specifications
Clearances
Oil pump : Pump housing - ring gear (runner) . . . .. . . . . .. .. . . .. . .

arc segment - ring gear . . . .. . . . . .. . .. .. .. .. . . . . . . . . .
axial clearance . . . . .......... . ...... . .... ... . .. .. .. .
8rake 80: Clearance between clutch pressure plate
and retaining ring . . .. . .. . .... .. .. . . .. ... .. . .. ... . . .
Clutch C2, brakes 81 and 82 :
Clearance between clutch pressure plate
and retaining ring . . ......... . ......... . . . . .... . . .. .
Input shaft, clutch CO, axial clearance ..... . . . . . . . . . .. . . .. ... .. .
Output shaft, axial clearance . . ...... .. . .. . . . . .. . .. . . .. .. . . ... .
0.07-0.15 mm (0.0027-0.010 in)

0.11-0.14 mm (0.0043-0.010 in)
0.02-0.05 mm (0.0007-0.0019 in)
0.35- 1.60 mm (0.01-0.06 in)
0.3-1.2 mm (0.01-0.05 in)

0.3-0.9 mm (0.01-0.04 in)
0.3-0.9 mm (0.01-0.04 in)
Transm ission fluid

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models to 1983 inclusive: ATF, type For G

Models from 1984 on: ATF, type Dexron II D
Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5 I (approx. 2.5 I in torque converter)
Transmission by model year and eng ine type

Model year Eng ine
Transmission
Volvo PIN
Model year Engine
Transmission
Volvo PIN
1990-
B 230 FT (Eur)1)
AW71 L
1208643
1987-
8280 E (No)
AW71
1208533
1990-
B 230 FT (USA)
AW71
1208642
1987-
B280F
AW71
1208532
1989-
B234F (USA)
AW72L
1208666
1986-
8230K
AW71 L
1208417
1989-
B 234 F (Eur)
AW72L
1208667
1985-
B200E
AW70
1208415
1989-
B230 FT
AW71
1208661
1985-1987 8230K
AW71 L
1208371
1989-
B200 F (Fi)
AW70
1208659
1985- 1987 828A
AW71
1208360
1989-
8230 F (Eur)
AW70L
1208652
1984-
AW71
1208334
1989-
B 234 F (Eur)
AW72L
1208638
1985-1987 819/8200 K
AW70
1208332
1989
B234 F (USA)
AW72L
1208637
1984-1985 819 E
AW70
1208314
1989-
B230 F2)
AW70L
1208604
1982-1987 B28E
AW71
1208310
1987-1988 B230F (USA)
AW70L
1208563
1985-1987 8230A
AW71
1208304
1987-
AW71
1208534
1984-1985 823E
AW71
1208300
1983-1987 B28F
AW71
1208248
1)
2)
B 280 E (Eur)
New turbocharger unit from 1990 on

USA, Canada, Japan , Australia
B23/8230 FT
AW70lAW711AW72L Automatic transmission

Specifications
Kickdown cable, torque converter

Length of cable
projecting into engine
compartment with cable
attached to
transmission
-~
Length, cable sleeve
-~
Kickdown cable
L!)
0)
--co"
0
0)
.....
.....
0)
-- .....
0
0
0)
0)
"
--"" --"..... --".....
" "
t::<O <0
Nt::
0
"0 0
0
0"
0)
Volvo PIN,
kickdown cable
Transmission Volvo PIN
1)
0)
L!)
0
(Y)
.....
0)
0)
-- -0
0
0)
0
0
:0
--,
(Y)
0)
0)
(Y)
N
(Y)
0)
0)
(Y)
(Y)
(Y)
0)
0)
(Y)
Q)
~ ~
.c .c
.c
"0
<:t <:t co 0
<:t <:t co
(Y)
0)
0)
(Y)
0
0
0
0
<:t <:t
<0
"
N N N N (Y) (Y) "

(Y)
.....
..... ..... ..... ..... ..... .....
0)
"
<0 N 0
co
co co co 0)
<:t
..... <0
<0 co
0) 0) 0) 0)
0
L!)
(Y)
L!)
(Y)
0
N
0
AW72L
AW72L
1208667
AW71
1208661
AW70
1208659
AW70L
1208652
AW72L
1208638
AW72L
1208637
AW70L
1208604
AW70L
1208563
AW71
1208534
AW71
1208533
AW71
1208532
AW71 L
1208417
AW70
1208415
AW71 L
1208371
AW70
1208314
AW71
1208310
AW71
1208304
AW71
1208300
AW71
1208248
1233359 to March 1982 inci.
L!)
(Y)
(Y)
(Y)
(Y)
N N N N
.....
..... ..... .....
N
<0
<0
0
N
N
0
0)
L!)
(Y)
0)
<:t
L!)
(Y)
N
N
<:t
(Y)
..... .....
"
0
0)
<:t
<:t <:t .....
(Y) (Y) co
.....
..... <0
0
1208666
1208332
(Y)
1208642
AW70
AW71
1208334
co co co L!)
<:t <:t <:t co co <:t
L!)
L!)
<:t <:t <:t
L!)
I)
AW71
0)
:J
1208643
1208360
0
..... 0<0 <0
0) .....
0
" ""..... "N.....
..... N"
N N ..... N
E E E E E E E E E
E E E E E E E E E
0)
AW71 L
AW71
"....."
<:t <:t
N N N N N N N N N
:0 ..J ..J ..J ..J
..J
..J
..J
..J ..J
"0 :0 :0
Q) .c .c
>- u>- u>;:
>- u>- u>- u>- u>~ --,
~
--,
u
u
~ :j
~
::::
~
Q) Q) Q)
Q) Q) Q) Q) Q) <0 <:t <:t <:t <:t <:t <:t <0 <:t
>- >- >- ~ >- >- >- >- >:J
Marking,
kickdown cable
Torque converter
.-
II
CD
10
CD
0
0
I')
It
. 1)

Specifications
Kickdown cable, torque converter

CO
1 off
Thickness of new plate
Min. dimension in
brackets ( ).
-~
(V)
.-
.-
E
E
E
E
80
3 off
r-:
.-
(V)
C1
0
.-
.-
E
E
-E
0
.-
"1
AW71 L
1208643
AW71
1208642
AW72L
1208666
AW72L
1208667
AW71
1208661
AW70
1208659
AW70L
1208652
AW72L
1208638
AW72L
1208637
AW70L
1208604
AW70L
1208563
AW71
1208534
AW71
1208533
AW71
1208532
AW71 L
1208417
AW70
1208415
AW71 L
1208371
AW71
1208360
AW71
1208334
AW70
1208332
AW70
1208314
AW71
1208310
AW71
1208304
AW71
1208300
AW71
1208248
r-:
"1
81
.-
......
82
3 off
lI)
cq
-E
.-
.-
<-
E
E
E
E
0
0
"1
......
83
50ff*
E
E
C2
4 off 3 off 1 off
"1
It
(V)
E
E
0
E
E
AW 70, 4 plates
AW70lAW711AW72L Automatic transmission

Specifications
Valve spring specifications

Spring for
Designation
in manual
Free
length
(mm)
Active
turns
Wire
dia.
(mm)
Outside
dia.
(mm)
Remarks
Accumulator B2
92
Accumulator C2
C2
Accumulator C1
Cl
66.7
68.3
66.7
61.2
55.2
32.2
43.6
68.6
64.8
20.6
21.9
43.0
31.4
14.0
13.0
12.0
11 .5
8.5
6.5
9.5
15.5
13.0
1.5
8.0
15.5
13.5
2.8
2.6
3. 2
2.5
2.0
1.6
1.8
2.0
2.0
0.9
0.7
1.2
0.9
17.3
17.9
20.4
16.5
15.9
14.7
14.3
17.5
17.2
9.1
8.6
10.9
8.9
AW70 (1208820, 284)

AW 70 (1208320)
AW71
AW70
AW71
AW 72 L, orange 2)
AW 72 L, blue 2)
AW70, AW 71
AW 70 (1208320)
59
59
4C
(39 )
29
19
3C
2C
lC
13C
25.6
27.3
37.6
36.1
42.4
35.1
34.6
11 .5
9.5
14.5
12.0
15.0
12.5
13.0
1.1
1.1
1.2
0.7
0.8
0.8
0.6
9.0
9.0
9.2
9.1
9.2
9.0
7.6
32.1
33.3
9.0
7.0
2.0
1,.
13.1
13.8
6C
6C
37.9
33.65
14.5
14.5
1.1
1.1
10.6
10.6
AW70
AW71
8C
BC
3A
9C
73.3
61.2
71 .3
37.8
15.0
13.0
15.0
12.5
1.6
1.8
1.9
1.1
16.7
17.2
17.4
9.6
AW70
AW71
9C
9C
37.0
37.4
13.0
13.5
1.1
1.1
9.6
9.7
10C
18.5
13.5
0.5
5.2
Governor valve
Kickdown va lve
Throttle valve
Detent regulator valve
Modulator valve, manual 3-2
type 1
type 2
Control valve , rear clutch
Governor modulator valve
Modulator valve, manual 2-1
Downshift valve manual 3--2
Downshift valve , manual 2-1
Shift valve, manual 4--3
Relief valve
By-pass valve
Shift valve 3-4
type 1
type 2
Primary valve
type 1
type 2
Secondary regulator valve
Signal valve , lock-up
Changeover valve, lock-up
1A
2A
69
AW70
AW71 , AW72L
AW70, AW71
earlier type, yellow
No spring
AW 70 L (1208652)
AW 72 L, green
AW71 L (1208417,643)
AW 70 L (1208563, 604)
dark red
white
Note: The table may be used only for identifying the springs during assembly. A spring is not necessarily defective if a
parameter, such as the spring length, does not agree exactly with the specified value . Special test equipment is requred to
determine whether or not the spring characteristics are acceptable.
1)
2)
A = Upper front valve body

B = Upper rear valve body
C = Lower valve body
Two springs in accumulator piston C2
AW70l AW 711AW72L Automatic transmission

Specifications
Accumu lator pistons, accumu lator spri ngs

Accumulator
piston
C1 C2
.;::
0.
0.
(/)
(/)
Q)
Q)
.c
.c
1208642
1208666
AW72L
1208667
AW71
1208661
AW70
1208659
AW71
AW72L
1
2
3
AW70L
1208652
AW72L
1208638 1
AW72L
1208637
AW70L
12086042
AW70L
12085632
AW71
1208534 12
1
AW71
1208533
AW71
1208532 1
AW71 L
1208417 12
AW70
1208415
AW71 L
1208371 1
AW71
1208360
AW71
1208334
AW70
1208332
AW70
1208314
AW71
1208310
AW71
1208304
AW71
1208300
AW71
1208248
~
o
::J
'0
1208643
82
OJ
.;::
::J
AW71 L
C2
(/)
OJ
C
C1
82
(/)
Accumulator springs
'0
M r-- M M 0
(0 '<I' (0 ..... N
M '<I' 00 r-- (0 N
(0 N
l!'l N
..... (0 '<I' (0 .....
N
N
00 l!'l (0 '<I' N
N
'<I' (0 (0 l!'l N
M r-- N
r-- l!'l M M M l!'l r-- r-- '<I'
0
00 ..... l!'l en 0
r-- 00 en 0 0 0 en ..... M ..... 00 00 en 0 ......................... en
en en 0 en 0 en en 0 en en en 0 0 0 0 0 0 N en en en 0 0 0 N N N '<I'
M M '<I' M '<I' M M '<I' M M M '<I' '<I' '<I' N
'<I' N O M M M '<I''<I''<I' 0 0 0 .....
NNMNMNNMNNNMMMl!'lMl!'ll!'lNNNMMMl!'ll!'ll!'lOO
'<I'
00
l!'l
l!'l
N
00
(0
'<I'
M M M
M M
Double springs in piston C2.

Double springs in B2.
From May 1985.
To April 1985 inclusive.
.g>
Replacement schedule - hydraulic control system
(!)
S2.
Although control systems are similar in principle, components may not be replaced by different types. This will create a serious risk of changing the gear positions or negating the gear change function completely. When replacing a complete control system , the
original system must be replaced by that shown in the table.
:to
2:l
~ );
~.
::J
Cl)
'J
.....
~
~
-.
New control
system
introduced
as from
serial No.
C')
(j)
C')
AW71
1208661
AW70
1208659
AW70L
1208652
AW72L
1208638
AW72L
1208637
AW70L
1208604
AW70L
1208563
AW71
1208534
AW71
1208533
AW71
1208532
AW71 L
1208417
84 HC 83266
AW70
1208415
84 HH 80206
AW71 L
1208371
AW71
1208360
84 HF 81193
AW71
1208334
84 JC 80001
AW70
1208332
AW70
1208314
84 HF 8045 1
AW71
1208310
84 JF 80751
AW71
1208304
AW71
1208300
AW71
1208248
84 HF 80196
I.!)
C')
C')
(j)
0
0
I'-
(j)
(j)
C')
CD
co 0
~
C')
-.:t -.:t
(j)
C')
I'-
(j)
(j)
C')
0
0
0
0
C')
I.!)
I'-
C')
C')
C')
C')
-.:t -.:t
~
C')
,....
-.:t
(j)
(j)
(j)
C')
I'-
C\J
(j)
(j)
C')
C')
(j)
0
N
0
--
r-
New control system

Volve? PI N
Original control system

Volvo PIN
co
(j)
(j)
(j)
0
0
0
0
0
0
-.:t
CD
-.:t -.:t N
N
(j)
(j)
C')
(j)
C')
-.:t -.:t -.:t -.:t -.:t -.:t -.:t -.:t -.:t 0

C') C')
,....
I.!)
C')
C')
C')
C')
C') C')
,....
,....
C')
C')
,....
I.!)
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I.!)
C')
C')
C')
I'- N -.:t I'-.:t -.:t -.:t (j)

co C") C!) -.:t
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AW70lAW711AW72 L Automatic transmissions

Torques
Torques
Important!
Automatic transmissions are manufactured almost exclusively from aluminium alloy (light alloy) with bolt and screw threads
cut directly in the material. Consequently, it is extremely important that the bolts and screws engage the th reads 'correctly and
that they are tightened to the correct torque.
Bolt location
Nm
(fUb)
Torque converter housing - engine , M 10 ..... . .. . .. . . . . . ... ... .

M 12 ... . .. .. . ...... . . .... . .
Drive plate - torque converter ............ .... .. . .. . .. . . ...... .
Centre support - gearbox housing :
Tighten alternately in steps of 7 Nm (5 ft.lb) . .. .. .. . . . .. . . . ... .
Pump body - pump cover ..... . . . .. .. .. ... . . .... ... . . . .. . . .. . .
Pump - gearbox housing . . .... .......... . . . . . . . ..... . .. . .... .
Parking pawl , locking plate .... . . . ... .. ........ .. ... . . .. . ..... .
Torque converter housing - gearbox housing
4 x M 10 .. . . ... ..... .. .. . . .. .. . . ... . . . . ... . ... . . . . . . . . . . . .
2 x M 12 . . . .......... .... .. . .. .. ... .. .... . ... . .. . ... . .. . . .
Rear extension housing - gearbox housing .. .. .... ...... . . .. . . .
Valve body, for cam , M 6 ... .. .. ................ .. . . .. .. . ... .. .
other bolts, M 5 . .. ... . . . .. .. . .. . .. .. . .. ..... . .. . . .
Strainer - lower valve body .. . .. . . ........ . .......... .. .. . ... . .
Cover plate - gearbox housing (governor), M 6 .. .. .. .. . ........ .
Control system - gearbox housing .. . ..... . . .. . .... . .... .... .. .
Oil sump - gearbox housing ... . .. .. . . ...... .... . .. . . . . ... .... .
Coupling flange - output shaft .... . . .. .. . . ... .. . . .. . .. ..... ... .
Plug, pressure gauge tapping . ... . ... ... . ... . ....... .... ... . .. .
Oil cooler connections - gearbox housing . . . . . ..... . . . .. .. . .. . . .
Speedometer drive, mounting . .... ... . .. ... . . . ... . .. .. . . . . . ... .
Nut, fluid filler tube ... . . . . ....... . .. . ... . . ... . . .. .. . . . . . . .. . . .
Solenoid valve .. ... .. . ... . ... .. . . . . . .. ..... .. .. . . .. . .. .. . ... .
Drain plug, oil sump .. .. . .. . . ... .... . .. .. . .. . . . . .. . .... .. .. .. .
35-50
55-90
41-50
(26--37)
(41-66)
(30-37)
24-28
6--9
22-28
6--9
(18- 21)
(4.5-6.5)
(16--21)
(4.5-6.5)
27-42
48-68
27-47
6--9
5-6
5-6
6--9
8-12
4-5
40-50
5-9
20-30
4-6
80-90
10-16
18-23
(20-31)
(34-50)
(20-35)
(4 .5-6.5)
(3 .5-4.5)
(3 .5-4.5)
(4 .5-6.5)
(6--9)
(3-3.5)
(30-37)
(3 .5-.5)
(15-22)
(3-4 .5)
(59-66)
(7-12)
(13-17)
* Use locking fluid 1161 053-2/1161 054-0
11

Special tools
Special tools
999
Description - use
1801 -3
2520-8
5070-1
Shaft - for installing needle thrust bearing in overdrive housing

Universal stand - for reconditioning work
Fixture - for reconditioning work
5071 -9
5072-7
5073-5
Extractor - for oil pump

Press tool - for removing/installing clutch return springs
Press tool - for removing return springs, brake 83
5075-0
5077-6
5117-0
Drift - for installing seal/drive flange in rear extension housing

Centering clamp - for aligning oil pump assembly
Drift - for installing oil pump seal
5070
148 215
2520
1801
5070
1361 20
5073
5072
5071
5075
148637
5075
12
148632
5077
119096
5117

Special tools
999
Description - use
5118-8
5149-3
5231-9
Drift - for installing gear selector shaft seal

Co unterhold - for holding drive flange
Storage tray - for valve body components
5241-8
5304-4
5394-5
Guide pins - for overdrive unit

Extractor - for removing drive flange from rear extension housing
Sleeve - for installing bearing in overdrive housing
5404-2
5971-0
Drift - for removing bush in rear extension housing

Mounting plate - for setting up dial gauge (measurement of axial clearance)
148319
5149
5118
5231
5304
I 148 282
5404
5394
5304
5241
.. 148 405
5971
13

Pre-dismantling instructions
Pre-dismantling instructions
Working procedures
The working procedures described are, as far as possible,
common to the different transmission types . Since the description is based on the AW 72 L unit (with lock-up and
kickdown inhibitor), some deviations may be noticed in the
illustrations. Differences which affect the working procedures are described in text and illustrations.
Do not prise apart components which are stuck. Instead,

tap carefully with a plastic mallet. Never employ sharpedged tools , but use well-rounded screwdrivers. Always
use a plastic mallet. See also under 'Control system,
general'.
Checking operation
Fold-out sheets
Three fold-out sheets are included at the rear of the
manual.
Sheet 1 shows the locations and names of the transmission components.
Sheet 2 shows the components of the upper and lower
valve bodies.
Sheet 3 shows the locations of the components in the top
of the lower valve body (left-hand side) and storage tray
5231, complete with valve body components (right-hand
side).
Dismantling
Inspect the transmission for leakage before dismantling.
Also try to identify any component or components which
may be faulty before these are dismantled.
Note: During disassembly of transmission components,

keep components in order removed on a suitable workbench. This will aid during transmission assembly.
14
Note: Use a piece of rubber sheeting to protect the

fingers when dismantling and checking the operation of
brake and clutch pistons with compressed air.
Cleaning and drying

Clean all oil passages thoroughly and blowout with compressed air.
Compressed air should preferably by used for drying components. Under no circumstances should rags or cloths
which may leave fluff or threads in the passages be used
for this purpose.
AW70lAW711AW72L Automatic transmissions, gearbox

Dismantling into main components

Special tools: 2520, 5070, 5071, 5073, 5149, 5241, 5404
The transmission is dismantled more or less in the numerical order indicated in the figure. See also fold-out
sheet 1, page 131 .
1.
2.
3.
4.
5.
6.
7.
Torque converter
Oil sump, oil pipes and control system
Extension housing and governor
Accumulator pistons
Gear selector mechanism
Oil pump and torque converter housing
Overdrive unit, CO-BO
8.
9.
10.
11.
12.
13.
Front clutch, C1
Rear clutch, C2
Centre support unit, B1-F1-B2
Planetary unit, F2
Brake piston + take-up sleeve, B3
Gearbox housing and components
15
AW70lAW711AW72L Automatic transmission, gearbox

A1
Clean unit externally
Locate leakage(s), if any.
, 148649
A2
(
Remove torque converter

Use both hands to withdraw from shaft.
Remove gear change lever

Remove solenoid valve and O-rings, kickdown
inhibitor switch , wiring and clips
1482 14
A3
5070
Attach fixture 5070 to gearbox. Mount fixture and

unit on stand 2520
Place container underneath stand to collect oil.
1482 15
A4
Measure and record axial clearances of input and
output shafts
Purpose is to check condition of needle thrust bearings.
Permissible clearance: 0.3-0.9 mm .
Use mounting plate 5971, magnetic stand and dial gauge.
16
AW 70l AW 711AW 72L Automatic transmissions, gearbox

AS
Remove:
- Oil sump and gasket.
- Particle magnets in sump.
(units without lock-up are fitted with one magnet only).
- Oil pipes (3 off) (2 on units without kickdown inhibitor).
- Prise each end alternately with a screwdriver.
- Fluid strainer complete with upper gasket, spacer and
lower gasket.
A6
\
Remove control system mounting screws (1 7)

Illustration shows location of screws on system with lockup function.
Illustration shows location of screws on control system

without lock-up function .
136 133
A7
Lift off control system assembly
Raise assembly slightly and release kickdown cable from
throttle cam .
17
AW 70lAW 711AW 72 L Automatic transmissions, gearbox

A8
Remove kickdown cable
Pull cable end as far as possible into housing . (Pull from
underneath .)
Press out cable end with 10 mm drive.
A9
Remove accumulator pistons and springs
Blowout pistons from underneath with compressed air at
reduced pressure of approx. 10 kPa. Hold hand over piston
to prevent damage.
146219
Note: Note spring arrangement. AW 72 L has double

springs in piston C2. Certain AW 70/71 units have double springs in C2 or B2. AW 71 (No. 1208534) and
AW 71 L (No. 1208417) have double springs in both B2
and C2.
A10
Remove :
- Retainer (1) and push rod (2).
- Parking pawl complete with spring and spindle (3).
A 11
Remove gear selector shaft and cam
Tap retaining ring to one side and knock out pin using drift.
Withdraw shaft and remove cam .
Remove shaft retaining ring . (Install new ring when reassembling.
18

A12
Remove oil seals from selector shaft
Prise out seals (2 off) with screwdriver.
A13
Remove :
- Drive flange . Use counterhold 5149.
- Extension housing and gasket.
- Spacer.
Use extractor 5304 if drive flange is seated firmly on shaft.
A14
Remove governor
Bend out locking tab and remove bolt and tab washer.
Remove locking spring, prise out end with screwdriver and
withdraw governor from shaft.
148224
A15
Remove :
- Governor oi l passage cover plate and gasket
- Fluid strainer. Use screwdriver. Take care to avoid damage to strainer!
19

A16
Remove oil pump mounting bolts (picture 1)

Insert gu ide pins 5241 (picture 2)
Remove torque converter housing using twisting/lifting action (picture 4)
Remove oil pump using extractor 5071 (picture 2)
Remove guide pins 5241 and O-ring (picture 5)
Remove torque converter housing bolts (6 off)

(picture 3)
Remove overdrive unit and clutch CO (picture 6)

Grip assembly and pull straight upwards.
A17
Remove front clutch C1 complete with bearing

race and thrust bearing
Lift clutch upwards.
, ' 148232
20

A18
Remove rear clutch bearing races and thrust

bearing
(Front race may remain seated in rear of clutch CO.)
Remove rear clutch C2

Grip as illustrated.
148233
A19
\.
Remove centre support unit

Remove bolts (2 off). Lift centre support unit as illustrated.
A20
Remove reaction plate retaining ring

Use large screwdriver. Prise out retaining ring and work off
by degrees using flat-nosed pliers.
A21
Remove planetary drive unit and brake 83 plate

assembly
A22
Remove brake 83 take-up sleeve
A23
Remove thrust bearing and race

(Rear thrust bearing, output shaft).
21

A24
Remove retaining ring securing brake 8 3 return

springs
Attach press tool 5073 as illustrated. Tighten tool bolts alternately until load on retaining ring is reli eved . Remove
ring using screwdriver.
Relieve return springs by undoing tool bolts alternately.
A25
Re move:
- Tool 5073.
- Spring press ure plate and return sp ring s
(Components are separate on some units).
A26
Remove brake 83 pistons

Position unit with front end facing downwards. Place rags in
fluid co llection container under unit to protect brake pistons.
Blow compressed air quickly and distinctly through hole.
A27
If pistons stick during removal, use flat-nosed pli ers to withdraw upper piston. Exert pu ll even ly arou nd circumference .
Carefu lly prise up intermediate piston using screwdriver.
Lower piston may be removed using two we ll rounded
we lding rods bent at the tip .
Illustration shows brake piston B3 complete.
22

A28
Remove:
- Oil cooler connections.
- Pressure tapping plugs.
148240
23
AW70lAW711AW 72L Automatic transmissions, gearbox

Overdrive unit, dismantling

Special tool: 5072
148 241
CO-FO-BO
81
Withdraw input shaft and clutch CO from overdrive housing
148242
82
Check operati on of freewheel FO before dismantling clutch

Hold clutch housing and turn input shaft.
Shaft should be free to rotate clockwise (A) and should be
locked in counterclockwise direction (8).
148243
24
AW70lAW 711AW72L Automatic transmissions, gearbox

83
Remove bearin g race and thru st bearing from
input shaft
(Front thrust bearing, CO).
AW 70/early AW 71: Two separate races and bearing .
Late AW 71/AW 72 L: One separate race and bearing with
race attached.
Check that neither thrust bearing nor race remains in rear
of oil pump housing opening.
148244
84
AW 71/72 L
Remove clutch from input shaft
148245
85
AW 70
Remove:
- Retaining ring .
- Brake hub.
Remove clutch from input shaft.
148246
25

Clutch CO, dismantling
Clutch CO, dismantling
C1
AW72 L
Remove:
-
Retaining ring (1).

Brake hub (2).
Friction plate (4).
Retaining ring (3).
Heavy steel plate (5).
Dished steel plate (6).
Note: Keep components in order removed to aid in assembly.
C2
co
4 3
AW70/71
Remove:
-
Retaining ring (1) (removed on AW 70).

Brake hub (2) (removed on AW 70).
Retaining ring (3).
Chamfered steel plate (4).
Friction plate (5).
Flat steel plate (6).
Note: Keep components in order removed to aid in assembly.
C3
Remove return springs

Compress springs using press tool 5072.
Remove:
-
Retaining ring.
Tool 5072.
Spring retainer.
Return springs.
C4
Remove clutch piston from housing
Blow through hole on inside with compressed air at reduced pressure of 100 kPa (43.5 psi). Block opposite hole
with finger.
If piston does not loosen, press back in and repeat.
C5
Remove O-rings from operati ng piston

136 185
26

Input shaft - planet gear carrier and freewheel FO, dismantling
Input shaft - planet carrier and freewheel FO, dismantling
01
Remove:
- Retaining ring (1).
- Pressure plate (2).
Plate functions as thrust bearing on AW 70 (2B).
- Freewheel Fa and outer race (3).
- Thrust washer (4).
- Thrust bearing AW 72 L (5).

AW 70 U71/71 L: Bearing and race (5B).
- AW 70: No thrust bearing.
- Oil passage plugs (4 off) (6) (AW 70/71 only).
02
Remove freewheel FO and retaining rings from

outer race
1. Bearing retainers (2 off).
2. Freewheel Fa.
3. Outer race.
27

Overdrive housing, dismantling
Overdrive housing, dismantling
E1
E2
Remove:
Remove:
- Brake assembly retaining ring (1).

Use screwdriver.
- Brake assembly pressure plate (2).
- Brake plates and spring plate (3).
No damper plate on AW 70.
- Bearing race (4).
- Ring gear (5).
- Bearing races (6) and thrust bearing (7). (Rear thrust
bearing, front ring gear).
- Brake piston retaining ring (8).

- Spring retainer (9).
- Return springs (10).
AW71/72 L: 12 springs (3 x 4)
AW70: 16 springs (4 x 4)
AW 72 L and late AW 71 :
Flat pressure plate (2); friction plates (3 off), thickness
1.7 mm (new).
AW 70 and early AW 71
Stepped pressure plate (2); friction plates (3 off), thickness
2.3 mm (new).
E3
Re move brake piston

Blowout piston through hole as illustrated. Use compressed air at reduced pressure of 100 kPa.
Withdraw piston using flat-nosed pliers if removal by compressed air is unsuccessful.
E4
Remove O-rings from piston
148250
28
AW 70l AW711AW 72L Automatic transmissions, gearbox

E5
Remove oil seals from overdrive housing

Unhook seals by hand.
14825 1
E6
Applicable only if need le thrust bearing must be

replaced :
Remove bearing from overdrive housing.
Tap out bearing using 25 mm o.d. sleeve .
29

Front clutch C1, dismantling
Front clutch C1 , dismantling

Special tool: 5072
148618
1.
2.
3.
4.
Retaining ring
Hub facing rear clutch
Front clutch hub
Thrust bearing and races (intermediate thrust bearing C1)
5.
6.
7.
8.
9.
10.
11.
Friction plate
Retaining ring
Clutch plates
Spring retainer with return springs and retaining ring
Clutch piston
Clutch housing
Thrust bearing and race
(Front thrust bearing C1)
F1
Remove bearing race and thrust bearing (11)

from input shaft
1486 17
30

Front clutch C1, dismantling
F2
6 5
4 3
Remove:
C1
148609
Retaining ring (1). Use screwdriver.

Hub facing rear clutch (2).
Front clutch hub (3).
Bearing races and thrust bearing (4).
Friction plate (5).
Retaining ring (6).
C1 clutch plates (7).
F3

AW72 L: 20 springs; AW70/71: 18 or 20 springs.
Compress return springs using tool 5072.
Remove:
- Retaining ring .
- Tool 5072 .
- Spring retainer and return springs .
F4
Remove clutch piston

Position clutch housing as illustrated. Cover two of the four
inside holes. Blow through one of the opposite holes with
compressed air at reduced pressure of 100 kPa.
If piston does not loosen completely, press back in and reneat.
F5
Remove O-rings from piston
119 023
31

Rear clutch C2, dismantling

Special tool: 5072
G1
Remove clutch assembly
Remove retaining ring.
Remove assembly.
Note: Order of components for assembly.
G2
5072

Compress springs using tool 5072.
Remove:
-
32
Retaining ring.
Tool 5072.
Spring retainer.
Return springs (18 off).
AW 70l AW 711AW 72 L Automatic transmissions, gearbox

G3
Remove clutch piston(s)
Position clutch housing as illustrated and blow through
either of the two upper inside holes with compressed air at
reduced pressure of 100 kPa.
Block opposite hole with finge r. If piston does not loosen
completely, press back in and repeat.
Note: Two-part piston on AW 70.
148253
G4
Remove O-rings
Remove rings (4 off).
~~~
~
AW70
r:::' -~
(~
~.::;;
AW71. AW 72
148254
33

Centre support unit, dismantling

Special tool: 5072
10
5 6
3
78
148 .613
1.
2.
3.
4.
5.
34
Clutch assembly B1
Spring retainer and return springs B1
Brake piston B1
Clutch housing
Brake piston B2
6.
7.
8.
9.
10.
Spring retainer and return springs B2

Freewheel F1
Brake hub
Clutch assembly B2
Sun wheel shaft

H1
Remove retaining ring from sun wheel shaft
H2
Remove centre support unit from sun wheel shaft
Freewheel F1 should remain in position on shaft.
148255
H3
Remove:
-
B1
Retaining ring securing brake B1 plate assembly.

B1 brake assembly.
Retaining ring securing brake B2 plate assembly.
B2 brake assembly.
B2
148256
H4
Remove 8 1 and 82 spring retainers and return
springs
Remove:
- Retaining ring.
- Tool 5072.
AW 72L :
B1: 12 springs attached to retainer.
B2: 20 springs attached to retainer.
AW70/71:
81
B2
B 1: 12 springs, separate or attached.

B2: 12 or 20 springs, separate or attached.
H5
Remove 8 1 and 82 pistons

Blow through holes with compressed air at reduced pressure of 100 kPa.
Allow pistons to drop out.
35
AW701AW71f'!4W72L Automatic transmissions, gearbox

H6
Remove oil seals (3 off)

'Unhook' seals by hand.
148 259
H7
Remove O-ring
Take care to avoid damage to seating groove.
HB
Remove O-rings from brake pistons
Take care to avoid damage to seating grooves.
148260
H9
Check freewheel F1
Hold brake hub and turn sun wheel shaft. Shaft should be
free to turn counterclockwise (A) and should lock when
turned clockwise (8).
Check that freewheel is not sticky or loose.
If necessary, replace brake hub complete with freewheel.
36

H10
Remove freewheel F1 and brake hub from sun
wheel shaft
H11
Remove oil seals (2 off) from sun wheel shaft
'Unhook' and pull off seals.
148263
37
\
Planetary drive unit, dismantling
1.
1B.
1C.
2.
3.
3B .
4.
4B.
5.
6.
6B.
7.
8.
Brake B3 plate assembly

Reaction plate
Pressure plate
Freewheel F2
Front end planet gear
Front ring gear
Rear planet gear

Sun wheel (AW 72 only)
Intermediate shaft
Ring gear
Output shaft
Thrust bearing , sun wheel
Front thrust bearing , output shaft
J1
Mount planetary drive unit in vice with soft jaws
Note: Shaft may be gripped only by splined section .
148264
38

J2
Remove brake 83 plate assembly

Lift off plate assembly.
Note whether freewheel F2 planet carrier accompanies
plate assembly. If so, support planet carrier by hand so that
it does not drop off. See operation J4.
J3
Remove front planet carrier and freewheel F2

Remove thrust washers (2 off) .
J4
If planet carrier accompanies plate assembly:

Separate planet carrier from plate assembly .
../
119 093
J5
Remove freewheel F2
Remove:
- Retaining ring.
- Freewheel F2 and washers.
- Pressure plate.
148267
39

J6
Remove front planetary ring gear
Use circlip pliers to compress retaining ring and lift off ring
gear.
J7
Remove:
- Intermediate shaft and rear planetary ring gear.
- Bearing race and thrust bearing.
(Front thrust bearing, output shaft).
J8
Remove rear planet carrier
Remove sun wheel (applies to AW 72 L only).
J9
AW70/71 :
Re move sun wheel bearin g race and thrust
bearin g
148271
40

J10
Remove ring gear from intermed iate shaft

Remove retaining ring.
i 148272
J11
AW72
AW72L:
Remove thrust bearing and race from intermediate shaft.
AW70/71:
Remove bearing race from intermediate shaft.
Remove seal
148273
J12
Remove output shaft from vice

Remove oil seals (3 off)
'Unhook' and pull off seals.
148274
41

Brake pistons B3, dismantling
Brake pistons 83, dismantling
148 6 11
K1
Separate brake pi stons

Separate the three pistons by hand. (Pistons may also be
removed one by one as described in operation A27 .)
Remove O-rings.
148275
AW 72 L, certain versions of AW 70/71 :

Springs (16 off) are attached to retainer.
Other versions of AW 70/71 :

Springs (16 off) and retainer are separate items.
148276
42

Oil pump, dismantling
L1
Remove oil seals (A)

'Unhook' and withdraw seals from pump housing .
L2
Remove retaining bolts (6 off) between front and

rear halves of pump housing
136178
Separate housing halves.

Remove O-ring .
L3
Check th at thrust bearin g or, alternatively, clutch

CO bearing race is not in locked position at rear
of pump housing opening
See operation 83.
L4
Mark position of gears

Mark top side with felt pen or similar instrument.
Important! Do not punch or scribe surface!
Remove gears.
43
AW70lAW 7 11AW 72L Automatic transmissions, gearbox

L5
Remove torque converter shaft oil seal

Use lever to prise out.
118354
44

Governor, dismantling
Governor, dismantling
c--1
@-2
M1
Remove:
-
Retaining ring (1).

Governor weight (2).
Valve stem (3).
Valve (4).
Spring guide (5).
(No guide in AW 70/71.)
- Springs (2 off) (6).
Only one spring (6) in AW 70/71.
AW70171
AW72L
45

Extension housing, dismantling
Extension housing, dismantling

Special tool: 5404
148 280
N1
Remove output shaft seal
Use lever to prise out.
N2
Check bushing
5404
Replace if worn or scored. See operation Z1 .
Remove bushing using drift 5404.
148282
46
AW 70l AW 711AW 72 L Automatic transmissions, gearbox

General assembly instructions

Replace all gaskets, O-rin gs and seals
Inspect all components for signs of wear, seizing, cracking etc.
Replace overheated or worn plates (grooves worn away).
See minimum dimensions under 'Specifications'.
Soak new friction plates for 15- 20 minutes in ATF fluid
prior to assembly.
Important! Use ATF, type F or G for models to 1983 inclusive , and ATF, type Dexron II D for models from 1984
on.
148 285
Wash all components except plates in cleaning

fluid
Blow clean with compressed air.
Wadding must not be used for cleaning .
Clean all oil passages carefully and blow clean with compressed air.
oo
Lubricate and grease components

Grease a -rings, seals and gaskets with a thin layer of
vaseline.
PIN
148284
1 161 151 -4
1 161 150-6
1 kg tin
22 g tube
Do not use gasket compound on gaskets.

Lubricate other moving components with ATF fluid.
Important! Use ATF, type For G for models to 1983 in clusive, and ATF, type Dexron II D for models from 1984
on .
Ensure that thru st washers and needle thru st

bearings are installed in correct positions
Use vaseline sparingly to hold in position . Too much vaseline may clog control system passages.
Check freedom of movement of balls in ball valves of
operating pistons CO, C1 and C2 .
148283
47

Clutch CO, assembly
Clutch CO, assembly

Special tool: 5072
01
Mount O-rings on clutch piston
Do not twist rings in grooves.
02
Install operating piston in clutch housing
Take care to avoid damage to O-rings.
03
Install return springs (1 8 off) and spring retainer
Ensure that springs are correctly seated .
04
Install retaining ring
Use tool 5072.
05
AW72L
Install:
3,6
1 2 4
CO~~~
_f(
48
148607
- Domed steel plate (1).

(Domed side outwards).
- Steel plate (2).
Position gap in body of housing, not in an opening (see
illustration).
- Friction plate (4).
Check thickness. See 'Specifications' for minimum dimensions.
- Brake hub (5).
illustration). See illustration.

Clutch CO, assembly
06
AW70/71
4,6
Install:
148 287
- Thin steel plate (1).

- Friction plate (2).
Check thickness.
See 'Specifications' for minimum dimensions.
- Chamfered steel plate (3)
.(Chamfer faces outwards).
illustration).
Brake hub (5).
illustration).
07
Check operation of clutch piston
Blow through one hole with compressed air at reduced
pressure of 100 kPa.
Cover other hole with finger.
'Sucking ' noise should be heard clearly.
148288
08
co
AW70
Remove :
- Brake hub (2).
These components are installed in operation P5.
49

Input shaft, planet carrier and freewheel FO, assembly
P1
Install:
- Oil passage plugs (4 off) (1).
(AW 70/71 only).
Use magnetic screwdriver.
- Needle thrust bearing and attached race (2) (Searing
and race are separate on AW 70 Land AW 71/71 L.
AW 70 is not equipped with separate thrust bearing.
- Thrust washer (3), with slots facing outwards.
P2
Reassemble freewheel (2) and outer race (2)
Install washers (1).
Note chamfer (arrowed).
P3
32
Install freewh eel assembly (1) in planet carrier

Note: Chamfered edge on freewheel should face towards
front (outwards) in planet carrier. See operation P2.
Install:
- Pressure plate (2).
Note: Thrust bearing side (raised side) of pressure
plate should face towards front (outwards) on AW 70.
148292
50

~~
rr::zzc
.. ~ , "'.....
P4
Reasse mble clutch CO and input shaft/planet

carrier
AW70
Ensure that planet carrier ,fits 'in 1j1ila:te ;assembly.
P5
AW70
148 293
Install:
- Brake hub (1).
illustration).
P6
Install thru st washer in rear of planet carrier

Apply vaseline to hold washer in position.
P7
Mount components of front needle thru st

bearin g, CO :
AW 72 L/late AW 71 (two components)
Install:
- Bearing race
Bearing with race attached is installed in oil pump when
assembling gearbox. See operation AZ19 .
148399
AW 70/early AW 71
Install:
- Inner (rear) bearing race
- axial needle bearing.
Outer (front) race is installed on oil pump when reassembling transmission. See AZ19.
148296
51

Overdrive housing, assembly

Special tools: 1801, 5394
148608
01
Check that plugs (2 off) are in position
148409
02
If replacing thru st bearing:
Install bearing in overdrive housing .
Press into position using tool 5394 and handle 1801 until
rim of tool is in firm contact with housing .
03
Install new oil seals
Hook seals together.
Check that seals are free to move in grooves.
148411
52

04
Install new O-rin gs
Inner and outer a-rings on brake piston BO. Do not twist
rings in grooves .
05
Install brake piston 80
Press in piston taking care not to damage a-rings.
148412
06
Install return springs
Versions differ in terms of number of openings in piston
and number of springs. If number of springs (12 off) is different to number of openings, locate springs symmetrically
as illustrated.
07
Install:
- Spring retainer.
- Retaining ring .
Use screwdriver. Position retaining ring gap in body of
housing, not in an opening (see illustration).
136456
08
Install rear thrust bearin g and front rin g gear
Install:
- Bearing race .
- Thrust bearing.
- Bearing race .
Use vaseline to hold in position .
Locate as illustrated .
1484 13
53

09
Install:
-
Bearing race (2) in ring gear.

Use vaseline to hold in position.
Ring gear (1).
Spring plate (3).
Position with convex side downwards.
148 298
010
Install:
- Brake BO plate assembly
Check friction plates. See 'Specifications' for minimum
dimensions.
Arrangement: Steel plate - friction plate - steel plate etc.
- Pressure plate
AW 70, certain versions of AW 71 :
Raised shoulder on pressure plate should face retaining
ring groove.
- Retaining ring
Position gap in body of housing , not in an opening .
1484 14
011
Check clearance between pressure plate and

retaining ring
Clearance: 0.35--1 .60 mm.
148415
012
Check operati on of brake piston

Hold one hand against pressure plate.
Blow with compressed air at reduced pressure of 100 kPa.
Check that plate assembly moves.
1484 16
54

013
Align plates
Use screwdriver.
014
Install input shaft/planet carrier
Check that thrust washer at rear of planet carrier is in position. (See operation P6)
Check that edge of clutch housing CO is approx. 3.5 mm
below edge of overdrive housing.
148 41 8
55

Front clutch C1, assembly

Special tool: 5072
R1
Install new O-rings on clutch piston
Do not twist O-rings in grooves.
R2
Install piston in clutch housing
Press down piston taking care to avoid damage to O-rings .
R3
Install return springs and spring retainer

AW 72 L: 20 springs.
AW 70/71 : 18 or 20 springs.
Ensure that springs are correctly seated.
R4
Install reta ining ring

Compress return springs with tool 5072.
Install retaining ring, ensuring that it is correctly seated in
groove.
Remove tool 5072.
56
AW70lAW7l1AW72L Automatic transmissions, gearbox

Front clutch Cl, assembly
R5
Install clutch C1 plate assembly
Check friction plates. See 'Specifications' for minimum
dimensions.
Install thin retaining ring after last plate. Position gap in
body of housing, not in an opening (see illustration).
Install last friction plate.
136212
R6
Install bearin g races and thru st bearin g
I Note : Note arrangement.
; 148420
R7
Align plates
Use screwdriver.
148 421
RB
Install:
- Front clutch hub (1).
Check that thrust bearing and races are in position.
Ensure that hub fits in plate assembly.
- Rear clutch hub (2).
illustration).
57

R9
Install front needle thru st bearing
Mount bearing race at rear of overdrive housing. Use vaseline to hold in position .
ca 39 mm
R10
Check operati on of clutch pi ston

- Assemble clutch C1 and overdrive housing.
Hold clutch housing CO with hand to ensure that housing does not drop out.
Check that distance between rear edges of CO and C1
clutch housings is approx. 39 mm.
148423
Blow through hole with compressed air at reduced pressure of 100 kPa as illustrated. Clutch and plate assembly
should now move.
R11
Remove clutch C1 from overdrive housing

Check that bearing race and thrust bearing are in position
as described in operation R9.
148424
58

Rear clutch C2, assembly

Special tool: 5072
S1
Install new O-rings (4 off) on clutch piston

Piston on AW 70 is in two parts.
r;.:~~
(~ .
~~
AW70
AW71, AW 72
148254
S2
AW 71/72 L:
Install piston in clutch housing.
AW70 :
Install inner, then outer piston
148 425
S3
Install return springs (1 8 off) and sprin g retainer
Ensure that springs are correctly seated.
148426
59

S4

5072
Install retaining ring, ensuring that it is correctly seated in

groove.
Remove tool 5072.
S5
Install plate assembly
Inspect friction plates. See 'Specifications' for minimum
dimensions.
Position pressure plate with chamfered side facing outwards towards retaining ring.
Plain pressure plate is fitted in certain AW 70 units.
148427
S6
Ensure that retaining ring is correctly seated in groove with
gap in body of housing, not in an opening (see illustration).
S7
Check clearance between retaining ring and
uppermost plate
Clearance: 0.3-1.2 mm
119049
S8
Check operation of piston
Blow through one of rear inside holes with compressed air
at reduced pressure of 100 kPa. Block opposite hole with
finger.
Plate assembly should move in direction of retaining ring .
148428
60

Centre support unit, assembly

Special tool: 5072
148299
T1
Install new oil seals

Install two seals on sun wheel shaft.
Check that seals are free to move in grooves .
148263
Install three seals on centre support.

148259
T2
Install new O-rings

- Brake piston B1: 1 ring.
- Brake piston B2: 2 rings .
- Centre support: 1 ring .
82
T3
Install brake 8 1 piston

Take care to avoid damage to O-rings.
148430
61

T4
Install brake 81 return springs, spring retainer

and retaining ring
AW 72 L is provided with 12 springs permanently attached
to retainer.
Springs (12 off) and retainers are separate in some AW 70/
715. Ensure that springs are correctly seated .

Compress springs using tool 5072. Install retaining ring,
ensuring that it is correctly seated in groove.
Remove tool 5072.
81
14843 1
T5
Install brake 82 return springs, spring retainer

and retaining ring
Install spring retainer and retaining ring using same procedure as for brake 81 described in T4 above.
AW 72 L is provided with 12 springs permanently attached
to retainer. Springs (12 or 20) and retainers are separate in
some AW 70/71 5. In the case of 12 springs, install in three
groups of four.
Ensure that springs are correctly seated .
148432
T6
Install brake 81 plate assembly

Inspect friction plate. See 'Specifications' for minimum
dimensions.
Arrangement: Light steel plate - friction plate - pressure
plate.
Pressure plate is chamfered on certain AW 70/71 5. Install
plate with chamfer facing outwards towards retaining ring.
148433
T7

gap in body of support, not in an opening (see illustration).
148434
62

T8
Install brake 82 plate assembly

Inspect friction plate. See 'Specifications' for minimum
dimensions.
Arrangement: Thin steel plate, followed alternately by friction and steel plates.
Install pressure plate with chamfer facing outwards towards
retaining ring .
Plain pressure plate is fitted on certain gearboxes.
148429
T9

gap in body of support, not in an opening (see illustration).
T10
Check clearance between retaining ring and

upperm ost plate
Clearance, B1 and B2 : 0.3-1 .2 mm
\
81
82
148 435
T11
"
81
82
Check operation of pistons

Blow through holes as illustrated using compressed air at
Plate assembly should move in direction of retaining ring.
63

T12
Install freewheel F1 and brake hub on sun wheel

shaft
.1
~
I III~~ I' .
148262
T13
Align plates with brake 82

Insert brake hub in plate assembly
148627
T14
Install retaining ring on sun wheel shaft
148255
64

Planetary drive unit, assembly
U1
Install:

Locate projections in planet carrier. Washer can be installed in one position only.
- Inner bearing retainer (2).
- Freewheel F2 (3).
Press in freewheel by hand with arrow pointing inwards
and flange facing outwards.
If freewheel is difficult to install, use discarded O-ring to

compress rollers as illustrated below.
- Outer bearing retainer (4).

Ensure that retaining ring is correctly seated in groove.
Installation of freewheel F2 with aid of O-ring .
148638
65

U2
Assemb le plate assembly reaction plate and front

planet carrier
U3
Check freewheel
Front planetary train should lock when turned in clockwise
direction and should be free to rotate when turned counterclockwise (in direction of arrow). Freewheel must not be
sticky or loose.
U4
Install brake 83 plates on front planet carrier

Inspect friction plates. AW 71172 L: 5 plates; AW 70: 4
plates. See 'Specifications' for minimum dimensions.
Arrangement:
AW71/72 L
Friction plate beside reaction plate, followed alternately by

steel plates and friction plates. Install pressure plate in outermost position.
AW70
11 9 092
Steel plate beside reaction plate, followed by plates in

same order as above. (AW 70 is equipped with only four
friction plates.)
us
Install oil seals
Install three seals on output shaft. Hook seals together.
66

U6
Install on intermediate shaft:

AW72 L:
Sun wheel bearing and attached race.

AW70/71:
Bearing race. Bearing is installed in rear ring gear. See

operation US.
Both gearboxes :
- Rear ring gear.

- Retaining ring.
AW 70/71
148 301
U7
Install new seal on front end of intermediate shaft
148628
UB
AW 70/71 :
Install needle thru st bearin g and bearing race on

intermed iate shaft.
119102
U9
Install rear planet carrier in rear ring gear.
1190B7
67

U10
AW72L :
Mount rear section of sun wheel shaft.
(AW 70/71 has integral sun wheel shaft).
U11
Mount output shaft in vice

Note: Use soft jaws in vice. Shaft may be gripped only
by splined section.
148629
U12
Mount front needle thrust bearing and bearing

race on output shaft
U13
Assemb le intermediate shaft and output shaft
148640
68

U14
Place front ring gear on top of rear ring gear

Locate retaining ring gap in opening provided by missing
tooth in output shaft coupling (arrowed in picture).
When correctly installed, width of retaining ring gap should
be same as tooth pitch on front ring gear.
119 106
U15
Install thrust washer in rear planetary train

Locate projections in recesses in rear planet holder.
AW 70/72 L: Nylon washer.
AW 71 : Steel washer.
U16
Install thrust washer in front planetary train

Locate projections in recesses in planet holder.
Use vaseline to hold in position .
AW 70/72 L : Steel washer.
AW 71: Nylon washer.
119091
U17
Assemble front and rear planetary trains

Ensure that thrust washers have remained in position and
that front planetary train is properly seated in front ring
gear.
Note: Hold planet holder and freewheel to prevent them
falling out of plate assembly.
69

Oil pump, assembly, cleaning and inspection
Oil pump, assembly

136178
Cleaning and inspection

V1
Clean all parts thoroughly

Note: Do not wash off markings on pump gears.
Dry components with compressed air.
Inspect all components .
Inspect particularly for signs of cracking, scoring and wear.
148630
Important! Since gears and pump halves are designed

to match closely, all components must be replaced if
anyone is found to be faulty.
V2
Inspect torque converter shaft bushing

Outward displacement of bushing will block drain passage,
causing oil leakage.
Replace pump if bushing has been displaced outwards or
is damaged .
70

Oil pump, assembly
Assemb ly
V3
Install gears in hub in accordance with markings
V4
Check clearance between housing and runner
Pull both gears forward (see arrow) and measure clearance with feeler gauges.
119 005
V5
Check clearance between top of teeth on runner

and crescent-shaped secti on of housing
Check clearance as illustrated .
V6
Check axi al clearance of both gears
Place steel rule across face as illustrated .
Measure axial clearance of both gears with feeler gauges.
Clearance : 0.02-0.05 mm
Remove gears.
148631
V7
Install new torqu e converter shaft oil seal

Use tool 5117.
Note: Take care to avoid damage to machined surface
on pump housing.
119096
71

Oil pump, assembly
VB
Oil all moving parts with ATF fluid
Important! Use ATF, type F or G for models to 1983 inclusive, and ATF, type Dexron II D for models from 1984
on .
V9
Re install gears in hu b in accordance with
markings
V10
Assemble pump housing halves loosely

Holes match in one position only.
Note: Finger-tighten bolts (5 off) only.
V11
Mount centerin g clamp 5077

Adjust housing halves until 8.5 mm cylindrical drift can be
inserted in each of seven bolt holes for assembly of pump
with overdrive unit.
148632
Tighten centering clamp 5077.
V12
Tighten bolts (5 off)

Torque : 8 Nm (6 ft.lb)
V13
Remove centering clamp 5077
V14
Fit O-ring around pump housing

Install oil seals on pump hub
148 633
72

Brake pistons B3, assembly
Brake pistons B3, assembly
X1
Install new O-ring s
Do not twist rings in grooves.
X2
Assemble pistons
Compress pistons by hand.
148635
73
AW 70lAW 711AW 72L Automatic transmissions, gearbox

Governor, assembly
Governor, assembly
~1
@-2
148 279
Y1
Oil all components with ATF fluid
Important! Use ATF, type F or G for models to 1983 inclusive, and ATF, type Dexron II 0 for models from 1984
on .
Y2
Install:
-
Valve stem (3) .

Spring guide (5) . (No guide in AW 70/71) .
Springs (6) (Only one spring in AW 70/71) .
Valve (4).
Install components in governor housing.
Y3
Install:
- Governor weight (2) .
- Retaining ring (1) .
Y4
Check that valve is not sti cking
74

Rear extension housing, assembly
Rear extension housing, assembly

Z1
If bushing only is to be replaced

Install new bushing.
New bushing is not provided with holes and may be located
in any desired position.
Use drift 5404.
Oil outside of bushing with ATF fluid .
Important! Use ATF, type For G for models to 1983 in clusive, and ATF, type Dexron II D for models from 1984
on.
148636
Z2
Install seal
Lubricate lip of seal as specified in Z1 above.
Mount seal on drift 5075 and press into position.
148637
75

Complete reassembly
Complete reassembly
Special tools: 2520,5070,5073,5118,5149,5241 , 5971
1.
2.
3.
4.
5.
6.
7.
Take-up sleeve and brake pistons B3

Planetary drive unit F2
Centre support unit B1-F1-B2
Rear clutch C2
Front clutch C1
Overdrive unit
Oil pump
The transmission is assembled more or less in the above

numerical order.
8.
9.
10.
11.
12.
13.
14.
15.
Torque converter housing

Torque converter
Governor
Rear extension housing, drive flange
Accumulator pistons
Control system and oil pipes
Oil sump
Prior to assembly, check that all component units are correctly assembled.
Ensure that needle thrust bearings and races are installed
in correct positions as shown in figure on page 77.
76

Complete reassembly
AW72L, AW70L
AW71
AW72 L
AW70171
2
AW 70
AW71
AW70LI71
1. Front thrust bearing, CO (AW 72 Ulate AW 71: two

components. AW 70/early AW 71: three components).
2. Intermediate thrust bearing, CO (not installed on
AW 70).
3. Rear thrust bearing, front ring gear.
AW72 L
148672
4.
*5.
6.
*7.
*8.
9.
Front thrust bearing, C1.

Intermediate thrust bearing, C1.
Rear thrust bearing, C1 .
Sun wheel thrust bearing.
Front thrust bearing, output shaft.
Rear thrust bearing , output shaft.
* Installed earlier during assembly of unit in question.
AZ 1
Turn gearbox housing into vertical position

Install brake 83 pistons
Take care to avoid damage to a-rings. Tool 5073 may be
used, with great care, to press down pistons.
77

Complete reassembly
AZ2
Install spring retainer and return spring s
Certain gearboxes are equipped with separate springs
(16 off) and separate retainer.
In this case, ensure that springs are correctly seated . Install spring retainer.
1483 13
AZ3
Install retaining rin g
Mount tool using two M10 bolts approx. 30 mm long.
Tighten bolts alternately, first by hand and then by wrench.
Ensure that spring pressure plate is not unevenly loaded.
Install retaining ring. Remove tool 5073.
Ensure that retaining ring is correctly seated in groove.
AZ4
Install output shaft thru st bearin g and bearing
race in gearbox housing
AZ5
Install take-up sleeve
Locate guide spigot on bottom edge of sleeve inside brake
piston flange locate guide spigot on side in recess in gearbox housing.
Position opening in sleeve opposite opening in gearbox
housing .
148304
78

Complete reassembly
AZ6
Install planetary drive unit and brake 83 plate

assembly
Align plates with grooves in gearbox housing . Align semicircular recess in reaction plate with corresponding recess
in plate assembly.
Lower assembly carefully into position.
AZ7
Install planetary drive unit retaining ri ng

Use two screwdrivers.
Position retaining ring gap between two splines as illustrated .
AZ8
Check operation of brake pistons 83

Blow through one of the two holes with compressed air at
'Sucking ' noise should be heard clearly when blowing has
stopped .
If piston does not move , dismantle and inspect.
AZ9
Ensure that freewh eel F1 brake hub is correctly

installed in brake 82 plate assembly
AZ 10
Install centre support unit

Note : Hold sun wheel shaft so that brake hub does not
slip out of position.
Insert bolts arrowed in picture. Finger-tighten only to avoid

mis-threading.
Note : Do not torque bolts!
79

Complete reassembly
AZ11
Install rear clutch

Align clutch with plates in centre support unit.
When correctly installed clutch splines should be flush

with or below sun wheel shaft splines (see illustration).
AZ 12
Install C1 rear thrust bearing and races

Use vaseline to hold races in position.
AZ 13
Install front clutch C1

Use small screwdriver to align plates in rear clutch C2.
80

Complete reassembly
AZ14
Assemble front clutch C1 with rear clutch C2

This will be facilitated by locking rear clutch plates in position. Blow through one of holes arrowed in illustration with
air at reduced pressure of 100 kPa.
Face of front clutch should be located slightly below edge
of gearbox housing. If too high, it is not correctly seated in
rear clutch. If oil pump is mounted in this position, rear
clutch plates will be irreparably damaged.
Check that C1 front thrust bearing is in place on input shaft.
(Bearing was installed as part of operation R9 .)
AZ15
Check that bearing race at rear of overdrive unit

is in position
Race was installed in operation R9.
148646
AZ 16
Install:
5241
- Guide pins 5241 for centering overdrive unit.

- Overdrive unit. Opening (arrowed) should face oil sump .
- a-ring.
AZ17
Check that face of clutch CO is approx. 3.5 mm

below edge of overdrive unit housing
81

Complete reassembly
AZ 18
Install torque con verter housing
Use vaseline to lubricate mating surface between overdrive
unit and torque converter housing.
Tighten
- 4 upper bolts (see illustration) to 35 Nm (26 ft.lb)
- 2 lower bolts (see illustration) to 60 Nm (44 ft.lb) .
AZ 19
AW72UAW71 (l ater type)
Install thru st bearing with attached race in rear of
oil pump
Rear race is already installed in clutch CO (see operation
P7).
AW70/AW71 (earlier type)

Install front bearing race in rear of oil pump
Thrust bearing and rear (inner) race are already installed in
clutch CO (see operation P7).
AZ20
Install oil pump
Press oil pump carefully into position . Pump can be fitted in
one position only due to hole configuration.
Remove guide pins 5241.
Apply sealing compound (PIN 1 161 277-7) to underside of
bolt heads.
AZ2 1
Tighten bolts (7 off)
Tighten alternately.
Torque: 22 Nm (16 ft.lb).
82

Complete reassembly
AZ22
Tighten centre support unit bolts

First tighten bolt nearest accumulator piston seats to 7 Nm
(5 fUb). Then tighten other bolts to same torque. Continue
tightening in stages to 14 Nm (10 ft.lb) and 21 Nm (15
ft.lb), and finally to 26 Nm (19 tt.lb) .
AZ23
Check operati on of 8 1, 82 and C2 pistons

Blow through holes indicated in illustration with air at reduced pressure of 100 kPa . 'Sucking' sound should be
heard clearly when blowing is stopped.
If pistons do not move, dismantle and inspect.
AZ24
Install:
- Oil strainer.
- Oil passage gaskets.
- Cover plate.
Torque: 6- 9 Nm (4.5-6.5 tUb)
AZ25
Install governor
- Tighten bolt with tab washer.
Torque: 4 Nm (3 tUb).
Bend locking tab into position against bolt head.
- Locking clip.
- Spacer.
148667
83

Complete reassembly
AZ26
Install:
- Rear extension housing (use new gasket).
Torque: 35 Nm (26 ft.lb) .
- Drive flange.
Secure bolt with thread locking fluid (PIN 1 161 053-2/1
161 054-0).
Use counterhold 5149.
Torque: 45 Nm (33 ft.lb)
AZ27
Check axial clearance of in put and output shafts

Use mounting plate 5971, magnetic stand and dial gauge.
Permissible clearance: 0.3-0.9 mm.
Turn shafts and check for freedom of movement.
AZ28
Install gear selector shaft and cam using new

retaining ring
Install new locking pin.
Position retaining ring over locking pin.
Lock ring in position by punching into recess beside pin.
AZ29
Install gear selector shaft oil seal

Use drift 5118.
84

Complete reassembly
AZ30
Install parking pawl, spring and shaft

Position spring as illustrated.
AZ31
Install push rod

Insert push rod in selector cam and install retaining plate.
Tighten bolts.
Torque: 7 Nm (5 tt.lb).
AZ32
Inspect accumu lator pistons

Replace worn or sticky pistons.
Install new O-rings.
<:l:>
I
B2
C2
C1
148 307
85

Complete reassembly
AZ33
Install accumulator pistons and springs
AW72 L:
Smallest piston with two springs is installed in middle (C2).
Remaining two pistons are dissimilar and cannot be installed incorrectly.
148 308
Ensure that correct springs are fitted with correct pistons.

See notes made when removing.
B2
C2
C1
yellow spring
blue spring (inner)
orange spring (outer)
black spring
See also list of springs under 'Specifications'.
82
C2
C1
148309
AW 70171:
Smallest piston is installed in middle (C2). Remaining two
pistons are dissimilar and cannot be installed incorrectly.
Install springs for these pistons as noted when dismantling .
Certain AW 70/71 units are equipped with double springs
(outer and inner) in piston B2 or C2. AW 71 (No. 1208534)
and AW 71 L (No. 1208417) are equipped with double
springs in both B2 and C2.
See also list of springs under 'Specifications'.
AW70/ 71
82
C2
C1
148310
86

Complete reassembly
AZ34
Install kickdown cable in gearbox housing
Use new cable.
Note: Cables differ depending on engines and transmissions. See 'Specifications'.
AZ35
Install control system
Attach kickdown cable to throttle cam
AZ36
Insert guide spigot (pilot) of gear selector cam in
groove in gear selector valve
AZ37
Place control system in position and insert bolts
(17 off)
Do not tighten bolts.
Illustration shows locations and lengths of bolts in transmission with lock-up function.
87

Complete reassembly
Illustration shows locations and lengths of bolts in transmission without lock-up function.
136133
AZ38
Tighten bolts
Tighten alternately.
Torque: 10 Nm (7.5 ft .lb).
AZ39
Install :
-
Inner gasket.
Spacer.
Outer gasket.
Suction strainer.
Bolts : M8 x 28, 5 off (system with lock-up)

M8 x 22, 6 off (system without lock-up)
Torque: 5 Nm (3.5 ft.lb).
AZ40
Install oil pipes

Control system with kickdown inhibitor is equipped with
extra pipe.
Tap pipes carefully into position with plastic mallet.
88

Complete reassembly
AZ4 1
Attach cable clip
Pull cable gently until throttle cam is about to move.
Check that cable is seated in throttle cam groove.
Secure clip 0.25-1 .0 mm from end of cable sleeve.
AZ42
Install particle magnet(s)
Ensure that magnet(s) are clean .
Install directly under control system suction oil strainer.
148657
AZ43
Install oil sump
Use new gasket.
Bolts: M8 x 14 (14 off with washers).
Torque: 5 Nm (3.5 ft .lb).
Fit new drain plug and seal.
Torque: 18-23 Nm (13-17 ft.lb) .
AZ44
Install:
- Oil cooler connections and new a -rings. Adjust connections to suit oil pipes in car.
- Pressure tapping plugs and new a -rings .
Torque: 8 Nm (6 ft.lb).
89

Complete reassembly
AZ45
Install torque converter

Mount converter on input shaft. Turn slowly and ensure
that unit engages splines and pump drive keyway.
AZ46
Check position of torque converter

Place steel rule against converter housing. Measure distance between rule and converter mounting lugs.
Permissible clearance :
AW70171: 16.2-19.6 mm
AW 72L: 15.5 mm
AZ47
5070
Remove transmission from stand 2520 and remove fi xture 5070 from gearbox
Caution! Ensure that torque converter does not drop
out. Do not tilt transmission forward .
1482 15
AZ48
Install solenoid valve

Use vaseline to hold O-rings in position.
Torque : 13 Nm (9 .5 ft.lb).
AZ49
Un its with kickdown inh ibitor only:

Install oil pressure switch
AZ50
Secure wi ring in cli ps on gearbox housing
90

Complete reassembly
AZ51
Install:
- Gear selector lever.
Torque: 14 Nm (10 ft.lb) .
148312
91
AW 70lAW711AW72L Automatic transmissions, control system

General
Control system
General
Control system with out

lock-up function
148316
Control system with

lock-up functi on
Hydraulic control systems have been modified successively over the years, the most significant advance being the introduction of the lock-up function . This may be a feature of
all transmissions used in combination with the B 230 FI
92
FT/K and B 234 F engines. Lock-up requires an additional

two valves - a control valve and a changeover valve. See
also Service Manual 4 (43) , Fault tracing, repair, maintenance, design and function (brown frame).
AW70lAW711AW72L Automatic transmissions, control system

General
Another major function which has been introduced is the
kickdown inhibitor. This is a feature of the AW 71 unit
combined with the B 230 FT (Europe), B 280 E and B 280 F
(excluding USNCanada) engines, and on the AW72 L unit
(excluding USNCanada).
Additional components required for the kickdown inhibitor
function are an oil pressure switch (arrowed in the illustration) and an extra oil pipe in the lower valve body (arrowed
in bottom picture).
Other, minor modifications have been made in addition to
these.
1ln .1\ 1
Working procedures
As far as possible, common procedures are used for recon ditioning different versions of the control system. Since the
description is based on the AW 72 L unit (with lock-up and
kickdown inhibitor), some differences may appear in the
illustrations. Differences which affect the procedures are
described in text and illustrations.
Fold-out sheets at the rear of the manual show the gearbox, control system and their components. These may be
of assistance when dismantling and reassembling the
units.
Important!
Never interchange components from control systems of different designs. Installing an incorrect component may alter
the gear change positions or render the changing function
inoperable.
See 'Specifications' regarding identification of gearboxes
and control systems.
Cleanliness
Strict cleanliness is important. The control system is extremely sensitive to dirt and other impurities.
Clean the work station and tools before commencing work.
Never use rags, wadding or paper which may leave behind
threads or fluff. Use compressed air for drying and cleaning.
Use a chamois leather if it is necessary to use a cloth for
drying.
Damage
Apart from mechanical damage which may occur when dismantling and reassembling, damage to the control system
is a rare occurrence. As a result, attention in the form of
thorough cleaning and inspection will usually suffice.
93

General
Removal of sticky valves

Under no circumstances maya valve which is tending to
stick or which is stuck in position be prised loose. Instead,
tap the valve body with a piece of wood or plastic.
Small valve retainers (lock washers and pins) which are difficult to reach may be removed with a magnet when the
spring force has been relieved .
Inspection du ri ng dismantling
When dismantling the valve bodies and separator plate, inspect the components for damage which may be respon sible for leakage.
Also inspect for foreign particles in the system. These may
provide an explanation for transmission faults.
Special tool - storage tray

Storage tray 5231 is an excellent tool for keeping track of
components when working on the control system. Use of
the tray minimizes the risk of losing a component or installing it in the wrong position.
Note : Always place the components in their proper
compartments as they are removed from the control
system.
The illustrations in the following sections show the correct

storage locations of the components.
148319
94
These locations are also shown in fold-out sheet 3 at the

rear of the manual.

Control system - dismantling into main components
See fold-out sheets 2 and 3 at rear of manual.

Top (gearbox side)
A.
B.
C.
D.
E.
Upper front valve body.

Upper rear valve body.
Lower valve body.
Front (facing torque converter).
Rear.
148320
Bottom (oil sump side)
C. Lower valve body.

D. Front (facing torque converter).
E. Rear.
AA1
Place control system on clean workbench
148650
AA2
Control system with lock-up function
Remove:
- Locking spring and plate.
- Gear selector valve .
- Cover plate and gasket.
14832 1
95
AW 70l AW711AW72L Automatic transmissions, control system

Control system without lock-up function:
Re move:
- Locking spring and plate.
- Gear selector valve .
- Cover plate and gasket.
AA3
Remove screws in upper front and upper rear
valve bod ies
Total number of screws : 10
AA4
Position control system with underside fac ing
upwards
AA5
Control system with lock-up function:
Remove screws (6 off) from underside
Press valve body with one hand to prevent it springing
clear of separator plate.

Remove screws (5 off) fro m underside
Press valve body with one hand to prevent it springing
clear of separator plate.
96

AA6
Slide lower valve body carefu lly to one side and
lift off
Hold gaskets and separator plate so that balls and springs
do not fall out of valve body.
Position body with gaskets and separator plate facing upwards.
148326
AA7
Place components removed in storage tray
148325
AAB
Leave separator plate and bottom gasket in position
.,-.,
Je:.---..:o;). -. .
.:..
-... ..
- . . ... -.
e .
Secure plate temporarily with one screw .

.... .
.
- -.
.,-
Screw: M5 x 12 .
e.
. '.
e ._ .
11 9169
97

Upper front valve body (AJ, dismantling
Upper front valve body (A), dismantling
18AI
G)
13A
1AI
u mmm l7AI
~Om
~--""""" 1 4A
SAi l
16AI
I
1A.
2A.
3A.
4A.
SA.
98
Kickdown valve.
Throttle valve.
Secondary regulator valve .
Cutback valve.
Throttle cam, complete .
14832 7
6A. Throttle valve stop.

7A. Throttle valve spring.
(adjusting washers may also be fitted)
8A. Rubber ball, dia. 5.5 mm (systems without lock-up
only)
AW 70lAW 711AW 72 L Automatic transmissions, control system

Upper front valve body (A). dismantling
AB1
Remove:
- Rubber ball (8A)
(applies only to control system without lock-up function).
- Throttle cam, complete (5A).
148328
AB2
Remove:
- Kickdown valve (1 A) .
- Throttle valve stop (6A)- Throttle valve (2A) and spring (7 A). Note number of adjusting washers, if fitted.
Place components in storage tray

See illustration for operation AB5.
148329
AB3
Remove secondary regulator valve (3A)

Remove one screw and move cover aside to release valve.
Note: Strong spring pressure!
148330
AB4
Remove cutback valve (4A)
11 9 472
99

Upper front valve body (AJ, dismantling
ABS
Note: Note locations! See also fold-out sheet 3.
100

Upper rear valve body (B), dismantling
Upper rear valve body (B), dismantling
~9B
181
(3B)11
148 332
1B. Downshift valve 3-2.

2B. Modulator valve 2-1 , manual.
3B. Governor modulator valve. Two versions: Aluminium
plug or steel valve + spring.
4B. Control valve, clutch C2.
5B. Modulator valve 3-2, manual.
6B.
7B.
8B.
9B.
10B.
Detent regulator valve.

Rubber balls (2 off), dia. 5.5 mm.
Shift valve 2- 3.
Rubber ball, dia. 5.5 mm.
Steel ball, dia. 5.5 mm .
101

Upper rear valve body (8), dismantling
AC1
Note: Before dismantling:
Remove all balls (3 rubber balls and 1 steel ball,

7B, 9B and 10B)
Place balls in storage tray. See illustration for operation
AC6.
.-
AC2
Remove downsh ift valve 3-2 (1 B) and retainer
148333
AC3
Remove cover plate, and valves 2B, 3B, 4B and
5B
( 3B )
, .
148334
AC4
Remove shift valve 2- 3 (8B)
148335
AC5
Remove detent reg ulator valve (6B)
Press in spring and lift out retainer with magnetic screwdriver.
102

Upper rear valve body (8), dismantling
AC6
Note: Note locations! See also fold-out sheet 3.
103

Lower valve body (C), dismantling
Illustration shows control

system with lock-up function
>y
- C
rlll..' ........iilO=e:::>
~ IS ~
5C
~BI6C
~SIlIll7C
~~~~iI ~Q 9C
1C
Be
~mnmlm~~
- -~
~tm> ~
10C ~;;-
1C.
2C.
3C.
4C.
5C.
Relief valve.
Downshift valve 4-3, manual.
Downshift valve 2-1, manual.
Control valve, rear brake 83.
Shift valve 1-2.
(One unit in earlier version of AW 70171).
6C. Shift valve 3-4.
104
7C. Regulator valve 0-2, manual.
BC. Primary regulator valve.

9C. Lock-up function signal valve .
10C. Lock-up function changeover valve.
11 C. Rubber balls (3 off), dia. 5.5 mm. (8all marked x installed only in units without kickdown inhibitor).
12C. Rubber ball (1 off), dia. 6.3 mm.

11 C
7C
.I
136255
Illustration shows control

system without lock-up
Items 1C-8C: See control system with lock-up function on

previous page. Valves 9C and 10C are omitted.
11 C. Rubber balls (4 off). dia. 5.5.mm. (Ball marked x installed only in units without kickdown inhibitor)
105
AW70l AW711AW72L Automatic transmissions, control system

AD1
..
., ,.:
....
-....
.
--'. . ...
. .
Remove separator pl ate and bottom gasket
:'~ .
(Plate is secured temporarily with one screw).

Note appearance and location of gasket.
. -.
8 ._
8 .
119 169
AD2
Remove:
lID
~
~
- Relief valve and spring (13C).

- Ball (dia. 9.5 mm) and spring (not used in control systems on earlier versions of AW 70 and AW 71) (14C).
- Rubber bali, dia 5.5 mm (15C).
- Rubber bali (dia. 6.3 mm) and spring (16C).
AD3
Place components in storage tray.
See illustration for operation AD13
Turn valve body upside down.
148339
AD4
Remove relief valve retainer (1 C)
Use flat-nosed pliers.
Note: Strong spring pressure. Hold spring with hand.
AD5
Remove primary reg ulator valve (8C)
Press in valve by hand .
Illustration shows control system with lock-up function .
Re move changeover valve (1 DC)

(Applies only to control system with lock-up function.)
148341
106

Lower valve body (C), dismantfing
AD6
Remove:
-
Cover plate.
Downshift valve 2-1 (3C).
Control valve for 83 (4C).
Shift valve 1-2 (5C).
148342
AD7
Remove cover, separator plate and gaskets

Note appearance and location of gaskets.
Control system with lock-up functi on:

7 screws.
148343
Control system without lock-up functi on:

6 screws.
148344
ADB
Remove:
- Shift valve 3-4 (6C).
- Lock-up signal valve (9C).
Prise out locking pin carefully with screwdriver.
148345
107

AD9
Remove regulator valve 0-2 (7C)

AD10
Remove downsh ift valve 4-3 (2C)

Two locking pins.
AD11
.12C
Remove rubber balls

Two or three balls, dia. 5.5 mm (11 C).
Ball marked x is installed only in units without kickdown inhibitor.
One ball, dia. 6.3 mm (12C)
148348
AD12

Three or four balls, dia. 5.5 mm (11 C).
Ball marked x is installed only in units without kickdown inhibitor.
108

A013

Note location of components! See also fold -out sheet 3.
148350
109


Cleaning
Clean all metal components thoroughly in a fluid such as
petrol, paraffin or trichloroethylene. Dry with compressed
air. If necessary to dry with a cloth, use a non-fluffy material
such as chamois leather. Colton wadding must not be
used under any circumstances!
Important! Only metal components may be cleaned
with a solvent.
Inspect valve bodies

Ensure that oil passages and other openings are clear.
Also check that valve bores are not abraded or worn.
Inspect valves
Check all valves for marks of abrasion or wear. Check freedom of movement in bores. If necessary, valves may be
polished carefully with extremely fine emery cloth.
In some cases , valves may stick only when the control system is installed, with no indication of a fault when dismantled.
148351
Faults of this nature are due to excessively close tolerances between valves and valve body, and to 'settlement'
of the control system when mounted on the gearbox. In
some cases, this type of fault may be corrected by polishing the valve carefully with extremely fine emery cloth.
Important: polish carefully.
Inspect kickdown valve spool

Check that spool is not worn or sticky.
136259
110

Check separator plate
oo
Check that plate is clean and that all holes are clear.
..-
- ..'.
. -.

o
0
1191 62
Measure valve spring lengths

See details under 'Specifications'.
ROSTfRITT STAl
helt "<dOl
Measurement may also be carried out as valves are installed in valve body.
111111111"111111"111
I
11I1I1 1 111'IlIlllllIrltlll~l+lli1.lIl lIl
13626()
111
AW70lAW 711AW72L Automatic transmissions, control system

Vaseli ne
Different control system types
Vaseline must not be used to hold valve balls in position.

This may cause the balls to stick!
Since control systems are modified continuously and since

they are designed specifically for different engine options,
it is extremely important that the particular system be reassembled exactly as dismantled.
Never force in a sticky valve

Check instead if dirt or burring is interfering with valve
movement. If necessary, polish carefully with extremely
fine emery cloth . Check carefully to ensure that valves,
springs and pistons are not jamming against edges of
valve body. Ensure that all components are installed in
their correct positions!
Never turn the valve bodies/control system upside down in
the course of work. Loose components may fall out. Follow
the procedure described!
Torques
Tighten screws only to the prescribed torque. Always tighten alternately.
Overtightening of screws may damage the threads or
cause 'settlement' of the control system . This, in turn , may
cause valves to stick.
Torques : M5 screws: 5-6 Nm (3 .5--4.5 ft.lb)
M6 screws : 6-9 Nm (4.5-6.5 ft.lb)
See also 'Specifications; Torques'.
Use new gaskets and balls

Always use new gaskets when reassembling the control
system. Check that the new gaskets are the same as the
originals.
Do not interchange components from

different versions of control system
Interchanging springs and valves may alter the gear
change positions or render the changing function inoperable.
The control system and governor are accurately matched
to ensure that the gear change positions are correct.
See 'Specifications; Replacement schedule - control system' if the complete system must be replaced by a later
version .
112
Absolute cleanli ness essential!

If cloths have been used for drying , despite the above recommendations, the components must be inspected carefully to ensure that no threads are left on the valves or in
the valve bodies.
AW 70/ AW 71/ AW 72 L Automatic transmissions, control system

Upper front valve body (AJ, assembly
Upper front valve body (A), assembly
ISA
1AI
SAl
I
148 327
Rubber ball, dia. 5.5 mm (8A) is installed only in transmissions without lock-up function.
Storage tray with components for upper front valve body

(1A-8A) removed .
See also fold -out sheet 3.
AE 1
Install throttle valve (2A), spring and kickdown

valve (1A)
Check spring dimensions under 'Specifications'.
Install spri ng (7 A) and adjusting washers

(if fitted )
Note : Install same number of adjusting washers as
when dismantling.
7A
148353
113

AE3
Install throttle cam, complete (5A)

Install:
-
Spacer.
Spring.
Cam .
Washer.
Screw.
Ensure that spring and cam are correctly installed. Tighten

screw.
Screw: M6 x 28.
Torque: 6-9 Nm (4.5-6 .5 fUb).
148354
AE4
Install secondary regulator valve (3A)

148 355
AE5
Install cover plate and tighten screws

Ensure that cover plate is correctly oriented so that it is not
bearing on kickdown valve and spring.
Screw: M5 x 12.
Torque: 5-6 Nm (3 .5-4.5 fUb).
1 11 9 178
AE6
Install cutback valve (4A)

- Valve (small end inwards).
- Spacer.
- Retainer.
148 356
114

AE7
Install throttle valve (6A) stop

Note: Position with flanges facing left (towards throttle
cam) as illustrated.
148357
AEB
Control system without lock-up fun ction:

Place rubber ball (SA), dia. 5.5 mm, in position.
148358
115
AW70lAW711AW 72L Automatic transmissions, control system

Upper rear valve body (B), assembly
38
158 :6 '
148332
Storage tray with components for upper rear valve body removed.
116

AF1
Install downshift valve 3-2 (1 B)

Install valve, plug and retainer.
Spring is installed in operation AF2 below.
AF2
Install sh ift valve 2-3 (8B)

Install spring in valve. Insert valve, plug and retainer.
AF3
Install:
- Modulator valve 2-1

- Governor modulator
used)
- Control valve, clutch
- Modulator valve 3-2
---
(28)
valve (38) (two types of valve are
C2 (48)
(58)
(3B)
14836 1
AF4
Install cover plate and tighten screws
5-6Nm
Screw: M5 x 12
Torque: 5-6 Nm (3.5-4.5 ft.lb).
148362
117

Upper rear valve body (8), assembly
AF4
Install detent regulator valve (68)

Press in spring with screwdriver and insert retainer.
AF6
Place balls in valve body

Install:
- Rubber balls (2 off), dia. 5.5 mm (78)
- Rubber ball, dia. 5.5 mm (98)
- Steel ball, dia. 5.5 mm (108)
148364
118

Lower valve body (C), assembly

Control system with
lock-function
rtlm
ftfl~~~
m
ise
~En I 6C
~_TICDl.OI
~~~ n j
~~=mtm~mm~
-~
-a~
, D~I~ ~
I
148338
Control system without

lock-upfunction
6C
I
11 C o /
7C
1C
I
136255
119

10C 8C 3C 6C 9C
Storage tray with components for lower valve body indicated.

5C
2C 13C
148350
AG1
Install relief valve (1 C)

Install ball, spring and retainer.
Note: Strong spring pressure.
Ensure that retainer snaps into position .
AG2
Install primary regulator valve (8C)

Install valve, spring-loaded valve, sleeve and retainer. (Two
types of retainer are used.)
Illustration shows control system with lock-up function.
Assemble small valve piston and sleeve. Insert valve with
rounded end first.
Press home components until they bottom.
148367
AG3
Install shift valve 3- 4 (GC)

Install spring, valve, plug and locking pin.
Note: Recess in plug should face outwards. Insert locking pin (length 15.5 mm) in hole in plug.
120

AG4
Install downsh ift valve 4-3 (2C)

Install sleeve with recess facing spring, followed by valve
and inner locking plug .
Ensure that components are not sticking in valve body.
Install inner locking pin . Pin should be located in groove in
locking plug.
Install outer locking plug with chamfer facing outwards.
Do not install locking pin at this point. (Pin is installed in
operation AG11.)
AG5
Install downsh ift valve 2-1 (3C)

Install rear brake 83 control valve (4C)
Install cover plate and tighten bolts
M5 x 12
Torque: 5-6 Nm (3.5-4.5 ft.lb)
148370
AG6
Install sh ift valve 1-2 (5C)

Install spring-loaded valve, valve, spacer and retainer.
Ensure that valve is not sticking in valve body.
AG7
Turn valve body upside down

Install control valve 0-2 (7C). Install valve, locking plug and retainer
Smaller end of valve should face inwards. Retainer should
be located in locking plug groove.
Note : Orientation of locking plug. Do not turn valve
body over until operation AG17. Loose components
may fall out.
148372
121

Lower valve body (e), assembly
AG8
Control system with lock-up function, AG8-AG10

Install lock-up function signal valve (9C)
Install valve spring, spacer and locking pin.
Locking pin should be located in hole in spacer.
AG9
Install lock-up function changeover valve (10C)

Assemble components.
Ensure that slot in valve sleeve is correctly aligned for retainer.
148374
AG10
Install changeover valve locking pin (10C)
AG11
Install locking pin for downshift valve 4-3 (2C)

Locking plug was installed in operation AG4.
Ensure that locking pin is seated in groove in plug.
148376
122

. 12C
AG12
Control system with lock-up function, AG12AG14
Install:
- Rubber balls (3 off), dia. 5.5 mm (11 C)
Ball indicated by x is installed only in units without kickdown inhibitor.
- Rubber ball, dia. 6.3 mm (12C)
148348
AG13
Install cover
Install:
-
Lower gasket (A) between cover and valve body

Separator plate (not illustrated)
Upper gasket (B) between separator plate and cover
Cover
Note: Gasket configurations are different. Separator
plate is installed between gaskets.
B
148377
Adjust cover in relation to other screw holes.

Cover must not be misaligned
Tighten screws (7 off)
Screw: M5 x 18
Torque : 5- 6 Nm (3 .5-4.5 tt.lb)
148378
AG14
Install cover plate and gasket
Screw: M5 x 12
Torque: 5- 6 Nm (3.5-4.5 ft .lb)
148379
123
AW70lAW711AW 72L Automatic transmissions, control system

AG15
Control system without lock-up function, AG 15AG 16:
Install :
11C
- Rubber balls (4 off), dia. 5.5 mm (11 C)
ft-+--~-!I
Ball indicated by x is installed only in units without kickdown inhibitor.
AG16
Install cover
Install :
-
Lower gasket (A) between cover and valve body

Separator plate (not illustrated)
Upper gasket (B) between separator plate and cover
Cover
Note: Gasket configurations are different. Separator
plate is installed between gaskets.
148380
Adjust cover in relation to other screw holes.

Cover must not be misaligned
Screw: M5 x 18
Torque : 5-6 Nm (3.5-4.5 ft.lb)
AG17
Turn over valve body
Illustration below shows control system with lock-up function. Positions of balls are the same as in system without
lock-up.
AG18
Place balls and by-pass valve (1 3C) in valve body
Install:- By-pass valve (13C). Place valve on top of spring.
- Ball and spring (14C)
(Not installed in control system on certain early versions
of AW70 and AW71)
- Rubber ball , dia. 5.5 mm (15C)
- Rubber ball and spring, dia. 6.3 mm (16C)
Place ball on top of spring.
1SC
124
1EfC
148339

Complete reassembly
Control system - complete reassembly

A
AH1
Inspect new gaskets

Illustration shows gaskets for lower valve body (C).
Upper and lower gaskets are different. Ensure that gaskets
are installed in correct positions with lower gasket (A) immediately adjacent to valve body.
148381
..
-------,'" ... ..
.
..
. . :. --5.,q@f.
...
.
...
1
.11
1'.--;-
't
.-I- ..
'
~ .
Check that balls, by-pass valve and valve retainers (including pins) are in position
Place lower gasket and separator plate on valve

body
e.
1I". I.'.'
"
AH2
'
11
Secure separator plate temporarily with one screw.
Screw:
M5 x 12
/'
~. .
148382
AH3
Place upper gasket (8 in figure above) on top of

separator plate
AH4
Check that all balls and valve retainers are in position in upper rear valve body (8 )
148 364
AH5
Place lower valve body on top of upper rear body

Ensure that gasket and holes correspond,
148383
125

Complete reassembly
AH6
Install screws
Finger-tighten only.
Screws : M5 x 52 (2 off)
M5 x 28 (1 off)
148384
AH7
Turn over valve body and remove screw securing

separator plate
148385
AHa
Check that throttle valve retainer in upper front

valve body is in position
Check that rubber ball is in position
148386
AH9
Place lower valve body on top of upper front

body
Ensure that gasket and holes correspond .
148387
126

Complete reassembly
AH10
Install screws in upper front valve body
Screws M5 x 20, 28 and 50.
148388
AH11
Control system without lock-up function,
AH11 -AH1 2:
Install screws in upper front valve body
See figure below.
Screws M5 x 22 and 28 .
AH12
Install cover plate and gasket
Use new gasket.
Finger-tighten screws.
Screws: M5 x 12 and 52 .
136280
AH13
Turn over control system
Insert screws in upper front valve body (5 off) and
upper rear valve body (5 off)
Check that gaskets are positioned correctly.
Screws: M5 x 18 (4 off), 20, 28 (4 off)
148389
127

Complete reassembly
AH14
Tighten all valve body screws

Tighten alternately and trom both sides.
Torque : 5- 6 Nm (3 .5-4.5 tt.lb)
11 9793
AH15
Install gear selector valve

Install locking spring and plate
Tighten screw.
Screw M5 x 40.
Torque: 5- 6 Nm (3 .5-4.5 tt.lb)
148390
128

Assembly of other components
Control system - assembly of other components

AJ1
Clean and inspect other components not yet included in reconditioning

Clean:
r~
- Oil sump
- Oil strainer
- Oil pipes (2 pipes in gearboxes without kickdown inhibitor
- Particle magnet(s)
Dry components with compressed air.
148391
I Note : Do not use cotton wadding!

Check components for cracks and other damage.
AJ2
Torque converter
Inspect torque converter throat
Excessive scoring of throat will result in leakage past oil
pump seal.
129

Index
Index
Operation
Identification of transm ission . ... .
Kickdown cable, specifications . . .
Lubrication . ...... .. ... .. .. . .... .
Product plate . . .. .. . . . . . . . . . . . . . .
Serial number ... . .... .. . ... .. . . .
Special tools . ..... . .... . ... . .. . .
Spec ifications . . .. ... . .. . ....... .
Torque converter, specifications . .
Torques . . ...... .. ... .. . .... . ... .
Page
3
6
5
4
4
12
Brake piston BO
Dismantling . . . . . . . . . . . . . . . . . . .. E3-E4
Assembly . . . . . . . . . . . . . . . . . . . . .. 04-05
Brake piston B1 /B2
Dismantling . . . . . . . . . . . . . . . . . . . . H5
Assembly. . . . . . . . . . . . . . . . . . . . .. T2-T3
Brake pistons B3
Dismantling . . . . . . . . . . . . . . . . . . .. K1
Assembly .. . . .. . .. . .. . .. .. .. . . . X1-X2
Page
Clutch piston C1
Dismantling . . . . . . . . . . . . . . . . . . .. F4-F5
Assembly . ... . ......... ... .. . . . R1-R2
31
56
6
11
Freewheels
FO ... . . . . . ......... . . ... . .. . ..
F1 ..... . . . .. .. .. . . . . ... . .. .. ..
F2, dismantling . . . . . . . . . . . . . . . ..
F2, assembly . . . . . . . . . . . . . . . . . ..
50
36
39
66
78

Dismantling . . . . . . . . . . . . . . . . . . .. A1D-A 12
Assembly . . . . . . . . . . . . . . . . . . . . .. AZ28-AZ
18
84
Governor
Dismantling . . . . . . . . . . . . . . . . . . .. M 1
Assembly . . . . . . . ..... ... . ...... Y1-Y4
45
74
Input shaft
Dismantling . . . . . . . . . . . . . . . . . . . . D1
Assembly. . . . . . . . . . . . . . . . . . . . .. P4
27
50
Oil pump
Dismantling. . . . . . . . . . . . . . . . . . .. L1-L5
Assembly ........ . . .... . . . . . . . . V1-V14
43
70
Overdrive housing
Dismantling ... . ... . ..... . .. .. . . E1-E6
Assembly .. . ... . ... ... .. . . . . .. . 01-014
28
52
Overdrive unit, dismantl ing . . . . . .. 81-85
24
Gearbox
Gearbox, complete reassembly . .. AZ1-AZ51
Dismantling into main
components . . . . . . . . . . . . . . . . . . . . . A 1-A28
General assembly instructions . . .
Names and locations of
components (fold-out) .. .. . . . . . . .
Operation
15
47
P1-P3
H9-H10
J5
U3
131
28
53
35
61
42
73
Centre support unit

Dismantling . . . . . . . . . . . . . . . . . . .. H1-H11
Assembly. . . . . . . . . . . . . . . . . . . . . . T1-T14
34
61
Planetary drive unit

Dismantling ........ .. . ........ . J1 -J2
Assembly. . . . . . . . . . . . . . . . . . . . . . U1 - U17
38
65
Clutch CO
Dismantling .. . . . . .. ... ...... . . . C1-C5
Assembly . .. . ..... . .. ... . . .. . .. 01-08
26
48
Rear extension housing

Dismantling ..... .. .. ..... . . . .. . N1-N2
Assembly . . . .. ... ... ... ... .. ... Z1-Z2
46
75
Clutch piston CO
Dismantling . . . . . . . . . . . . . . . . . . .. C4
Assembly . . ... . .. . . .. ..... .... . 01 - 02
26
48
Clutch C2
Dismantling ... . .. .. ... . . .. . . ... G1-G4
Assembly . .. . .. . . . . . .. . .. . . . ... S1-S8
32
59
Clutch piston C2
Dismantling . . . . . . . . . . . . . . . . . . . . G3-G4
Assembly. . . . . . . . . . . . . . . . . . . . . . S 1-S2
33
59
Clutch C1
Dismantling. . . . . . . . . . . . . . . . . . .. F1-F5
Assembly . . . . . . . . . . . . . . . . . . . . . . R1-R11
30
56
Control system
Clean ing and inspection . . . .
Complete reassembly . .... . .. .. . .
General . . .... .. ... .. .. .. . .. . . .. .
Replacement schedule . .. .... .. '. .
Valve spring specifications . ..... .
110
125
95
92
10
8
Lower valve body

Dismantling .... ........ .... . ... AD1-AD13 104
Assembly ... ...... ....... . . .. . . AG1-AG18 11 9
137

Index
Operation
Oil pipes
Removal ...... . .... .... .. ... .. . A5
Installation. . . . . . . . . . . . . . . . . . . .. AZ40
Separator plate
Removal . . . . . . . . . . . . . . . . . . . . . .. AD1
Installation. . . . . . . . . . . . . . . . . . . .. AH2
Lock-up function . ... . .. .. ... . .. .
Kickdown inhibitor . . . .. . .... .. . . .
138
Page
17
88
106
125
92
93
Operation
Page
Upper front valve body

Dismantling ..... .. ....... . ... . . AB1-AB5
Assembly ... . .. . ... .. ... . . . .. .. AE1-AE8
98
113
Upper rear valve body

Dismantling . . . . .. . ........... . . AC1-AC6
Assembly. . . . . . . . . . . . . . . . . . . . . . AF1-AF6
101
116
Gearbox - component names

and locations
Brake piston BO
Clutch piston CO
Clutch piston C1
Brake B2
Clutch housing CO
Freewheel FO
Front planetary train
Planetary train, overdrive

(4th gear)
Clutch housing C2
Intermediate shaft
Centre support unit
148 673
Lower valve body (C) with lockup function
Upper front valve body (A)
18
13A '
1AI
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m
ise
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~onm l
SAl
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16AI
CI
Ci
I
rNffftI1frm
en
~~J==iitVW1!rnW\MonT[-m~~
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148 327
148338
Lower valve body (C) without

lock-up function
Upper rear valve body (8)
1BI
. I
OJ
V'{'('{'{'{'{rWAI
rrrrrrrmrml
(38)11
~, ~
2
1C
11 C
1C
IUIWI
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oQ.
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NIII.',~I/IIN
.....
"C
eN_
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'"
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ex>
to>
to>
7A6A 68
Locking spring
18 10C 8C 3C 6C 9C
Plate
Gear selector valve
:e se
::'0
::::r~
n m
0(0
(I)
"C .....
o ~
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CJ1
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388811-16C
78,9-108
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148350

AW7x Rebuild PDF

Uploaded by

AW7x Rebuild PDF

Uploaded by

Section 4 (43)

Volvo Cars North America

AW 70l AW 711AW 72 L Automatic transmissions

Pre-d ismantling instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dismantling into main components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox, dismantling of components

General assembly instructions . ... ......... ... . '''. ' . . . . . . . . . . . . ..

Gearbox, assembly of components

Gearbox, complete reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control system, general. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

Control system, dismantling into main components . . . . . . . . . . . . . .

Control system, dismantling of components

AW70lAW711AW72L Automatic transmissions

Index, page 137

We reserve the right to make alterations without prior notification.

AW 70/AW 71/AW 72 L Automatic transmissions

AW 70/AW 71/AW 72 L Automatic transmissions

The product plate on the unit specifies:

1208638 - Volvo part number (as from 1983)

AW 70lAW 711AW 72 L Automatic transmissions

Oil pump : Pump housing - ring gear (runner) . . . .. . . . . .. .. . . .. . .

0.07-0.15 mm (0.0027-0.010 in)

0.3-1.2 mm (0.01-0.05 in)

Transm ission fluid

Models to 1983 inclusive: ATF, type For G

7.5 I (approx. 2.5 I in torque converter)

Transmission by model year and eng ine type

Model year Engine

1985- 1987 828A

1987-1988 B230F (USA)

New turbocharger unit from 1990 on

AW70lAW711AW72L Automatic transmission

Kickdown cable, torque converter

N N N N (Y) (Y) "

1233359 to March 1982 inci.

AW 70lAW 711AW 72 L Automatic transmissions

Kickdown cable, torque converter

Transmission Volvo PIN

4 off 3 off 1 off

AW70lAW711AW72L Automatic transmission

Valve spring specifications

AW70 (1208820, 284)

Changeover valve, lock-up

A = Upper front valve body

AW70l AW 711AW72L Automatic transmission

Accumu lator pistons, accumu lator spri ngs

Transmission Volvo PIN

Double springs in piston C2.

Replacement schedule - hydraulic control system

Transmission Volvo PIN

New control system

Original control system

-.:t -.:t -.:t -.:t -.:t -.:t -.:t -.:t -.:t 0

I'- N -.:t I'-.:t -.:t -.:t (j)

AW70lAW711AW72 L Automatic transmissions

Torque converter housing - engine , M 10 ..... . .. . .. . . . . . ... ... .

* Use locking fluid 1161 053-2/1161 054-0

AW 70lAW 711AW 72 L Automatic transmissions

Shaft - for installing needle thrust bearing in overdrive housing

Extractor - for oil pump

Drift - for installing seal/drive flange in rear extension housing

AW70lAW711AW72L Automatic transmissions

Drift - for installing gear selector shaft seal

Guide pins - for overdrive unit

Drift - for removing bush in rear extension housing

AW 70lAW 711AW 72 L Automatic transmissions

Do not prise apart components which are stuck. Instead,

Note: During disassembly of transmission components,

Note: Use a piece of rubber sheeting to protect the

Cleaning and drying

AW70lAW711AW72L Automatic transmissions, gearbox

Dismantling into main components

AW70lAW711AW72L Automatic transmission, gearbox

Remove torque converter

Remove gear change lever

Attach fixture 5070 to gearbox. Mount fixture and