'95 D1 auto trans service?

[Paul K]

All:

Where's the best place to find step-by-step instructions on how to service an automatic transmission on my '95 D1? I searched here- found a lot about the DII but nothing on the D1. YouTube wasn't much help either.

Thanks,

Paul.

 

[stu454]

Do you kmow anything of its history? How many miles on it? What color is the fluid on the dipstick?

 

[ezzzzzzz]

I'm going with the notion that you simply want to change the filter and fluid as basic maintenance. I'm attaching some info from the RAVE that includes access and torque values. In general I have seldom done a transmission fluid service without mishaps. If you perform the task I would suggest installing an inline filter, Magnafine, in the return hose from the cooler. It will capture all of the fine debris in the fluid before it returns to the sump. The internal filter is only good for stopping loose hardware and small animals.

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[FONT=&quot]13 [/FONT][FONT=&quot]MAINTENANCE[/FONT]
[FONT=&quot]RENEW AUTOMATIC GEARBOX FLUID AND OIL[/FONT]
[FONT=&quot]SCREEN[/FONT]
[FONT=&quot]1. [/FONT][FONT=&quot]Site vehicle on lift or level ground. Place[/FONT]
[FONT=&quot]container to drain gearbox fluid into. Disconnect[/FONT]
[FONT=&quot]battery negative lead.[/FONT]
[FONT=&quot]2. [/FONT][FONT=&quot]Remove gearbox dipstick, located at rear of right[/FONT]
[FONT=&quot]hand rocker cover, to aid oil drainage. Release[/FONT]
[FONT=&quot]plug from bottom of sump and allow fluid to drain[/FONT]
[FONT=&quot]completely.[/FONT]
[FONT=&quot]3. [/FONT][FONT=&quot]Refit plug using a new sealing washer. Tighten[/FONT]
[FONT=&quot]to 10 Nm[/FONT]
[FONT=&quot]Refill ZF Automatic Gearbox and Check Fluid[/FONT]
[FONT=&quot]Level.[/FONT]
[FONT=&quot]NOTE: The fluid level must checked when[/FONT]
[FONT=&quot]fluid is cold and engine idling in park.[/FONT]
[FONT=&quot]4. [/FONT][FONT=&quot]Ensure vehicle is on level ground.[/FONT]
[FONT=&quot]5. [/FONT][FONT=&quot]Refill or top-up with correct quantity and grade of[/FONT]
[FONT=&quot]fluid. See LUBRICANTS, FLUIDS AND[/FONT]
[FONT=&quot]CAPACITIES, Information, Recommended[/FONT]
[FONT=&quot]Lubricants and Fluids[/FONT]
[FONT=&quot]6. [/FONT][FONT=&quot]Start and run engine. Apply footbrake, select[/FONT]
[FONT=&quot]position 1 then back to park. Check fluid level,[/FONT]
[FONT=&quot]this must be between the two marks on the[/FONT]
[FONT=&quot]dipstick.[/FONT]
[FONT=&quot]Oil screen replacement ZF automatic gearbox.[/FONT]
[FONT=&quot]See AUTOMATIC GEARBOX, Repair, Oil Screen[/FONT]
[FONT=&quot] [/FONT]
[FONT=&quot]ZF[/FONT]
[FONT=&quot]9 [/FONT][FONT=&quot]REPAIR[/FONT]
[FONT=&quot]OIL SUMP[/FONT]
[FONT=&quot]Service repair no - 44.24.05[/FONT]
[FONT=&quot]Remove[/FONT]
[FONT=&quot]1. [/FONT][FONT=&quot]Site vehicle on a four post ramp [hoist].[/FONT]
[FONT=&quot]2. [/FONT][FONT=&quot]Disconnect battery negative lead.[/FONT]
[FONT=&quot]3. [/FONT][FONT=&quot]Raise vehicle.[/FONT]
[FONT=&quot]4. [/FONT][FONT=&quot]Drain oil and refit plug with new seal.[/FONT]
[FONT=&quot]5. [/FONT][FONT=&quot]Detach heat shield at front exhaust pipe to[/FONT]
[FONT=&quot]manifold.[/FONT]
[FONT=&quot]6. [/FONT][FONT=&quot]Disconnect electrics from Lambda sensors.[/FONT]
[FONT=&quot]7. [/FONT][FONT=&quot]Remove catalytic converter assembly.[/FONT]
[FONT=&quot]8. [/FONT][FONT=&quot]Remove chassis cross-member from under[/FONT]
[FONT=&quot]gearbox.[/FONT]
[FONT=&quot]9. [/FONT][FONT=&quot]Disconnect dipstick tube at oil sump. Loosen[/FONT]
[FONT=&quot]securing bolt at bell housing and move dipstick[/FONT]
[FONT=&quot]aside.[/FONT]
[FONT=&quot]10. [/FONT][FONT=&quot]Remove clamps securing oil sump. Note their[/FONT]
[FONT=&quot]locations for refit and withdraw sump.[/FONT]
[FONT=&quot]11. [/FONT][FONT=&quot]Remove gasket and clean gasket mating faces.[/FONT]
[FONT=&quot]Refit[/FONT]
[FONT=&quot]12. [/FONT][FONT=&quot]Refit oil sump using a new gasket.[/FONT]
[FONT=&quot]13. [/FONT][FONT=&quot]Connect dipstick tube to oil sump and tighten[/FONT]
[FONT=&quot]bolt at bell housing.[/FONT]
[FONT=&quot]14. [/FONT][FONT=&quot]Refit chassis cross member.[/FONT]
[FONT=&quot]15. [/FONT][FONT=&quot]Refit catalytic converter assembly[/FONT]
[FONT=&quot]16. [/FONT][FONT=&quot]Connect electrics to Lambda sensors.[/FONT]
[FONT=&quot]17. [/FONT][FONT=&quot]Connect heat shield front pipe to manifold.[/FONT]
[FONT=&quot]18. [/FONT][FONT=&quot]Connect battery.[/FONT]
[FONT=&quot]19. [/FONT][FONT=&quot]Refill gearbox using correct grade of oil. See[/FONT]
[FONT=&quot]LUBRICANTS, FLUIDS AND CAPACITIES,[/FONT]
[FONT=&quot]Information, Recommended Lubricants and[/FONT]
[FONT=&quot]Fluids[/FONT]
[FONT=&quot] [/FONT]
[FONT=&quot]44 [/FONT][FONT=&quot]AUTOMATIC GEARBOX[/FONT]
[FONT=&quot]10 [/FONT][FONT=&quot]REPAIR[/FONT]
[FONT=&quot]OIL SCREEN[/FONT]
[FONT=&quot]Service repair no - 44.24.07[/FONT]
[FONT=&quot]Renew[/FONT]
[FONT=&quot]1. [/FONT][FONT=&quot]Site vehicle on a four post ramp [hoist].[/FONT]
[FONT=&quot]2. [/FONT][FONT=&quot]Disconnect battery negative lead.[/FONT]
[FONT=&quot]3. [/FONT][FONT=&quot]Raise vehicle.[/FONT]
[FONT=&quot]4. [/FONT][FONT=&quot]Drain oil and refit plug with new seal.[/FONT]
[FONT=&quot]5. [/FONT][FONT=&quot]Detach heat shield at front exhaust pipe to[/FONT]
[FONT=&quot]manifold.[/FONT]
[FONT=&quot]6. [/FONT][FONT=&quot]Disconnect electrics from Lambda sensors.[/FONT]
[FONT=&quot]7. [/FONT][FONT=&quot]Remove catalytic converter assembly.[/FONT]
[FONT=&quot]8. [/FONT][FONT=&quot]Remove chassis cross-member from under[/FONT]
[FONT=&quot]gearbox.[/FONT]
[FONT=&quot]9. [/FONT][FONT=&quot]Disconnect dipstick tube at oil sump. Loosen[/FONT]
[FONT=&quot]securing bolt at bell housing and move dipstick[/FONT]
[FONT=&quot]aside.[/FONT]
[FONT=&quot]10. [/FONT][FONT=&quot]Remove clamps securing oil sump. Note their[/FONT]
[FONT=&quot]locations for refit and withdraw sump.[/FONT]
[FONT=&quot]11. [/FONT][FONT=&quot]Remove gasket and clean gasket mating faces.[/FONT]
[FONT=&quot]12. [/FONT][FONT=&quot]Remove securing screws and detach oil screen[/FONT]
[FONT=&quot]and suction pipe, taking care to retain suction[/FONT]
[FONT=&quot]pipe spacer, discard ’O’ ring seal.[/FONT]
[FONT=&quot]13. [/FONT][FONT=&quot]Detach suction pipe from oil screen, discard ’O’[/FONT]
[FONT=&quot]ring seal.[/FONT]
[FONT=&quot]14. [/FONT][FONT=&quot]Clean oil screen and blow out with airline.[/FONT]
[FONT=&quot]15. [/FONT][FONT=&quot]Clean suction pipe.[/FONT]
[FONT=&quot]16. [/FONT][FONT=&quot]Fit new ’O’ ring seals to oil screen using light[/FONT]
[FONT=&quot]grease to aid assembly.[/FONT]
[FONT=&quot]17. [/FONT][FONT=&quot]Fit oil screen and suction pipe with spacer and[/FONT]
[FONT=&quot]secure with three bolts.[/FONT]
[FONT=&quot]18. [/FONT][FONT=&quot]Refit oil sump using a new gasket.[/FONT]
[FONT=&quot]19. [/FONT][FONT=&quot]Connect dipstick tube to oil sump and tighten[/FONT]
[FONT=&quot]bolt at bell housing.[/FONT]
[FONT=&quot]20. [/FONT][FONT=&quot]Refit chassis cross-member.[/FONT]
[FONT=&quot]21. [/FONT][FONT=&quot]Refit catalytic converter assembly[/FONT]
[FONT=&quot]22. [/FONT][FONT=&quot]Connect electrics to Lambda sensors.[/FONT]
[FONT=&quot]23. [/FONT][FONT=&quot]Connect heat shield front pipe to manifold.[/FONT]
[FONT=&quot]24. [/FONT][FONT=&quot]Connect battery.[/FONT]
[FONT=&quot]25. [/FONT][FONT=&quot]Refill gearbox oil system using correct grade of[/FONT]
[FONT=&quot]oil. See LUBRICANTS, FLUIDS AND[/FONT]
[FONT=&quot]CAPACITIES, Information, Recommended[/FONT]
[FONT=&quot]Lubricants and Fluids[/FONT]
[FONT=&quot] [/FONT]
[FONT=&quot]ZF[/FONT]
[FONT=&quot]1 [/FONT][FONT=&quot]SPECIFICATIONS, TORQUE[/FONT]
[FONT=&quot]TORQUE VALUES[/FONT]
[FONT=&quot]NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are[/FONT]
[FONT=&quot]tightened to the correct torque.[/FONT]
[FONT=&quot]Nm[/FONT]
[FONT=&quot]Coupling shaft to mainshaft 42* ......................................................................[/FONT]
[FONT=&quot]Filler tube to sump 68 .....................................................................................[/FONT]
[FONT=&quot]Gear change lever to gearbox 25 ...................................................................[/FONT]
[FONT=&quot]Cooler pipe adaptor to gearbox 42 .................................................................[/FONT]
[FONT=&quot]Securing screws - clutch F 10 .........................................................................[/FONT]
[FONT=&quot]Securing screw - parking pawl 10 ...................................................................[/FONT]
[FONT=&quot]Securing screws - pump 10 ............................................................................[/FONT]
[FONT=&quot]Intermediate plate plugs (M20) 50 ..................................................................[/FONT]
[FONT=&quot]Intermediate plate plugs (M14) 40 ..................................................................[/FONT]
[FONT=&quot]Bell housing mounting bolts 46 .......................................................................[/FONT]
[FONT=&quot]Governor mounting screws 10 ........................................................................[/FONT]
[FONT=&quot]Extension housing bolts 23 .............................................................................[/FONT]
[FONT=&quot]Control unit mounting bolts 8 .........................................................................[/FONT]
[FONT=&quot]Sump plug 10 ..................................................................................................[/FONT]
[FONT=&quot]Mounting screws for sump 8 ..........................................................................[/FONT]
[FONT=&quot]Drive plate to converter 39* .............................................................................[/FONT]
[FONT=&quot]Gearbox to engine 42 .....................................................................................[/FONT]
[FONT=&quot]Strut (threaded end) 42 ...................................................................................[/FONT]
[FONT=&quot]Bottom cover to converter housing 9 .............................................................[/FONT]
[FONT=&quot]Cover - converter housing 9 ...........................................................................[/FONT]
[FONT=&quot]Drive plates to crankshaft adaptor 40* ............................................................[/FONT]
[FONT=&quot]Adaptor to crankshaft 84 .................................................................................[/FONT]
[FONT=&quot]NOTE: * These bolts must have threads coated with Loctite 270 prior to assembly.[/FONT]
[FONT=&quot]Torque values below are for all screws and bolts used except for those that are specified otherwise.[/FONT]
[FONT=&quot]METRIC Nm[/FONT]
[FONT=&quot]M5 6 ......................................................................................................[/FONT]
[FONT=&quot]M6 9 ......................................................................................................[/FONT]
[FONT=&quot]M8 25 .....................................................................................................[/FONT]
[FONT=&quot]M10 45 ...................................................................................................[/FONT]
[FONT=&quot]M12 90 ...................................................................................................[/FONT]
[FONT=&quot]M14 105 ..................................................................................................[/FONT]
[FONT=&quot]M16 180 ..................................................................................................[/FONT]
[FONT=&quot]UNC / UNF[/FONT]
[FONT=&quot]1/4 9 ......................................................................................................[/FONT]
[FONT=&quot]5/16 24 ...................................................................................................[/FONT]
[FONT=&quot]3/8 39 .....................................................................................................[/FONT]
[FONT=&quot]7/16 78 ...................................................................................................[/FONT]
[FONT=&quot]1/2 90 .....................................................................................................[/FONT]
[FONT=&quot]5/8 136 ....................................................................................................[/FONT]
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[luckyjoe]

...I would suggest installing an inline filter, Magnafine, in the return hose from the cooler. It will capture all of the fine debris in the fluid before it returns to the sump.

Any details on this install? Do you have to shorten the return line or fab one to fit it?

 

[Rockbeard]

if it's high mileage, it could be a gamble on how it performs after you service it. drain some fluid out, hopefully it's nice and red which means it's been well maintained, and you should be ok. if you're dropping the pan, do observe all torque specs and directions above and use the proper recommended fluid. good luck!

 

[robertf]

Drain and refill. Adjust the throttle valve to 1mm lash. I don't think changing the filter is worth the effort. Mine has 275k and the original filter and still gets me to work and back. I think if it were clogged to the point of needing replacement the transmission would have had another failure and need rebuilding anyway

 

[Paul K]

Thanks guys. I haven't checked the colour of the fluid, but it's got well over 100k on the ODO & spent 10 years on Hawaii. I was thinking a transmission fluid, filter & seal swap. Seems to hard shift more than it should.

 

[ezzzzzzz]

The internal filter doesn't clog. Hell, it probably is rated at 100 microns to ensure a steady flow of fluid. The inline filter (simply cut out a section of cooler hose, fit and hose clamp in place) is closer to 10 micron I believe. It will capture most of the band particles and metal dust preventing it being recycled through the transmission. Much of this material falls to the bottom of the sump but any going through is effectively grinding paste slowing but surely accelerating wear.