10 Automatic Gearbox ZF 3 HP-12B Specification Power flow diagram Hydraulic control Special tools 10.00 10.05 10.10 10.11 10.15 10.20 10.21 10.25 10.30 10.35 10.40 10.45 10.50 10.55 10.60 10.65 10.70 1075 10.80 10.85 10.87 10.90 2.48. Aditon ‘Adjustment of linkage to carburettor Checking gearchange points Checking adjustment of selector lever Adjusting selector lever Gearbox — removal and refitting Torque convertor ~ removal and refitting Renewal of driving disc - Renewal of input shaft radial seal Oil pump ~ removal and refitting Renewal of support shaft Selector unit ~ removal and refitting Control system layout ©) position and valve housing . . b) pump housing and manifold depression valve housing Multi-plate clutches A and B ~ removal, refitting and dismaniling Multi-disc brakes C’, C, D and sun wheel set — removal, refitting and dismantling Renewal of output shaft radial seal Centrifugal governor — removal and refitting Renewal of output shaft ball bearing. . Parking lock ~ removal and refitting . . Renewal of acclerator shaft and selector lever sealing rings Renewal of starter lock and reversing lamp switch Oil cooler... - Fault-finding chart Page GA2 Page 2/1 Page 2/2 -Page 3 Page 4 Page 6 Page 7 Page 7/2 Page 8 Page 11 Page 12 Page 12 Page 12 Page 14 Page 14 Page 17 Page 18 Page 19 Page 25 Page 35 Page 36 + Page 38 Page 41 Page 42 Page 44 = Page 44/1 - Page 45 GAIZF Automatic Gearbox 3 HP — 12/B Specification Fully cutomatic 3speed gearbox with hydrodynamic torque convertor Ratios: Convertor 1-22:1 Ist gear 25621 Ondgeor «152: rd gear 10:1 Reverse 20:1 Oil grade: Automatic Transmission Fluid Type A. Approx. 475 litres (10.0 US pints or 8.4 Imp. pints) = initial Filling Approx. 1.5 litres (32US pints oF 2.6 imp. pints) at ol change Output shoft bell bearing end floc! 0,05 mm (0,00197") Mult-plte eich body A, 8 end float 02~03 mm * (ooa7e7-0.01181") Copa 0-0.15 mm (0-0.00571") mox Locating plate ~ circlip end float Torque convertor: BMW2000=Wwhite spot | Gearchange points: BMW 1800 Nw 2000, st-2nd gear 45—50 kph 45-55 koh (2-31 mph} (27-34 mph) 2nd=8ed goor 85-90 kph 85-95 keh (53-56 mph] (63-59 mph) | Hydraulic pressure readings and connections for BMW 6082 tester Convertor oil pressure (1) Selector position 0, accelerator linkage detached, engine speed 1000 rpm = 16 até (2276 psi). Accelerator linkage in kickdown position (hand- hold) = .35 ato (49.78 psi Clutch A (2) position A, accelerator linkage disconnected, handbrake on, footbrake operated, engine speed 1000 rpm 0-53eN (71.12~75.38 psi). Accelerator linkage in kicedown position hand-held) = 70-723 of (99.56-103.83 psi ‘Main pressure setting () position 0, accelerator linkage iconnected, engine speed 1000 rpm = 5.0 at (71.12 psi) Accelerator linkage in kickdown position (hand-held) = 7.0 atl (99.56 psi. Gear change throttle valve pressure (4) position 0, acce- lerotor linkage disconnected, engine speed 1000rpm = (09-1.2 att (12.80-17.07 psi Accelerator linkage in 35-37 att. (4978-5263 psi) Governor pressure (5) position A, vehicle speed 50 kph (S1.1 mph) = 13-15 ot6 (4.27-7.1 psi edown position (hand-held) = Tightening torque values for bolts and nuts 05-06 mkp (36-43 fib} 1.0 mkp (72 lb) 1.0mkp (72 ft/lb) Studs in georbox casing Parking lock mounting Driving shaft Oil pump. 1.0 mkp (7:2 fib) Oil sump LO mkp 72 fib) | ‘Speedometer drive bush 10 mkp (7.2 lb) Selector unit 0.4 mkp (43 fib) Torque convertor driving plate 20:+04 mkp (145429 fu) Convertor dome closure bolts, gearbox extension AM 10 x 1 1.5 mkp (10.8 Hb), Ga2 Convertor dome closure bolts, AM 18 X15 ‘Sorter lock and reverse switch Bearing flange and gearbox extension Convertor dome to gearbox Collar nuts, output side Cooler valve on convertor dome Hollow serew ~ return line 35 mkp (25. fib) 25 mkp (25. flb) 23 mkp (164 fib) 23.mkp (164 Fels) 12.0-15.0 mkp (268-1085 fl) 33 mkp (23.7 fib) 33 mkp (22.7 fib) aeww = ® Tt Neutral 2nd geor Power Flow 3 HP-12/8 9 Input shoft 3 Clutch A 10 Free wheel 4 Clutch 8 11 Free wheel 5 Disc brake C 12 Free wheel ®@ O@OOOOD Tt Ye. = rE os ®@ O©OOOE Wit: aGA 22any Jeajuod oynmuphy GA 23Buon fy woyssod gions Y Joxuos aynDsphy GA 24GA 25—) Mey scl : yh dOVE| er aBowen uowsod apron, jf Jowo> >yam4phySL ZL Jouuos syapapiy CA 28Sawer YY voused emons c Jouuo> 2yaD4pAy GA 298L Zl OL SL "re él =a Jouuo> 2ynoupAy Gamooz sth Tah . dOVElY a ee 5 L vii! =H ; 6ke ~ l = ee g TY t FH Ae : a Ls af o Jouuo> syamphy ry ny a ca 2mOL Jouuos ynmapky, Ga ane_ ia i (ee * f st a ™ pian — Ly = lL dOVZLY iu HE ey i ipa EE : L| ES ee Ko —-} L ‘an — : 8 Ox | 6 8L 42 a LI} 1 ane zi || | [ eee Seer - © | = | wa fl wT ar = a 7 6 oul | & ON Jouuos oyam4phydelusonuojeddoy z dwodpjooy | anej2ej@8 Ap 9881105 Oz sBokosquis.panossyiowy 6 Bokouah panes wy BL ‘eBokoiquue p snass|uowy Z| ez et et et aA wy @Bokoique,p auuof, 94 snoyo|n80H St ‘epupuuie> ap euuo,, ‘Spuowwo> 9p UOIsid EL pune ep euuen ZL ‘@puowwo> ep UOitld L] ‘9B020)q 6p ouUuDA OL ‘98000|q 9p ouuDA 6 ‘opuowo> ep o4inpe4 uojsseid op uoKsid @ ‘9puowiuo> ep oqnpga ue u sod op won Z Uojsteud ep Uoisid 9 ajdno> ap snassiyenuoy Z eduiog | ‘opuower Ip oyopls euoyssoud out ‘opucwo> 1p yop pH ayoiuid ouorssoud euc [ap 90A0U098 BIOAIOA 0%, 0188022014 IP DIONIOA OL AeL-PAY 086022019 IP DIONIoA 6 4 8 uo|85014 OJONOA L y8 201P9I08 02, 294990047090 YPIB|D BL wns0e KpInI BL wy ‘nor jo1juo> eBuDyp-190D L 14.9 oye jossua> 40}02940090 LOWY 9 iowyd euojsteid OjOrjoA § OAJOA [01)UO> 20J019}0220 UIOW S o> auojssoid BONA F Jon sapontiog ¥ ‘anon ALO & soponuod Z ddwnd Asowtg Leqanpstyenn 0 soyduppsBuniddny ot sejduppsBunjddny gh seydwppsBuajddny Z{ yuorsBunjddny, 9 JO#PPUPJOsSOAPIIOWPS JanYpruplOssoup| OPS L imjuerprupjartospidaoy ¢ JworPAUPLe|PUOAN Y wwenprupldeoH € J0IPLONA 7 edundsputtg |ws Special tools (automatic gearbox 3 HP — 12/B) Tool No. Purpose BMW Drive flange to check freedom of movement in half-moon pump... : : ws 6083 Hand exiractor for removing sleeves between selector Screw-in handgrips for removing and refitting the torque converier . a 6028 Tensioner for removing ond refitiing the Seager clips on the cup springs 6002 Punch for driving home radial zeal in half-moon pump . . 6080 Punch for driving home radial seal in gearbox extension 6029 Bracket clamp for mointenanee work on gearbox while removed from vehicle . se - 60024 Tensioner for removing ond refitting the circlip in front of the locating plate a - 6031 GA3 2.68 dionSpecial tools for automatic gearbox 3 HP - 12 B =p 1 Bmw Purpose Teo! No. Tool for checking torque converter for leaks 6082 Extractor for radial sealing ring in gearbox extension 6051 Exiractor for radiel sealing ring in crescent pump 6051-1 10.00 Adjusting throttle linkage Exact kickdown stop (1) and adjust. Note: For bosic adjustment purposes the stop guide (1) (top edge of bolt to bottom edge of stop guide) should be set to a length of 66.5 mm (2.618%) Fig. ‘When the pedal is fully depressed, joint (F] may just touch the floor carpet, but the latter should not act as a stop. (See Fig. 6) Correction is effected by corresponding adjustment of the stop guide (1) Remove locking clip (2) at ball joint Disengage tie rod (3) from operating spindle. Fig.2 asb uote uedo jou ysow 2.68 Aiton10.05 Checking gearchange points Check egjusiment of linkage to carburettor (procedure yo.00). With the pedal plete (13) fully depressed, the joint (F) should not be resting on the carpet. Move hand selector lever ~ gear levar ~ to position 0. Press down the occelerator pedal plate to the kickdown position (10). In this position, length “C" of thrust rod {6} must be codjusted until the edge of the operating lever (0) is tligned with mark (B). Remove ball joint securing clip. Detach thrust red (E) Looren locknuts (14). Gas Fig. 6 ‘Adjust red to length C by means of ball joints (15). Tighten ond secure bell joints ogcin. Refit thrust red (E} and secure with spring clip. Important: Any attempt 1o drive the vehicle with thrust rod (€) disconnected will damage the gearbox. ‘Adjust engine idling speed to approx. 800 spe. Test runs In position A with the accelerator fully depressed but riot in kickdown position, the gearbox should change from Ist 10 2nd at 45-50 kph (27-31 mph) [45-55 kph ‘= 27-24 mph and into Srd ot 85-90 kph (53-56 mph) [85-25 koh = 53-59 mph Important: Jf change occurs too early, lengthen thrust rod (E). If change occurs too late, shorten thrust rod (E}. By using the kickdown ~ eccslerotor pedal position (13) =the vehicle may be driven in each gear up to its maximum permitted engine speed. ia. 6 + BMW 2000 A and 2000 CA ory20}29)95 1yo4 04 9194880 8q P| (2800 -jsod puo (2) uid Bup~po} use (:r6e00) Ww gL xcddo jo apuaiDa/> y ond J0422I8 snow po! s0129)95 «poieg junow Buybeq Jo ssouuny Yay, 9.68 Altecstion Tana sexpjou ou) Aq, pouy Pie) 0 vouttod of quo: “8A9| pUOY We Gam” ae10.11 Gear lever adjustment 1. Push spring catch (1) forward and lift the gote (2) out with care Fig. 79 2. Looten selector lever sleeve nut (6) with hook span- ner (HS). When refiting: Screw the selector lever sleove nut up. wards to within 0.078" (2mm) approx. of the geor shaft handle and coat the resulting gap with Loctite. 2, Screw the selector lever handle (3) together with its ‘sociated rod (4) out of the lever assembly (5). Fig. 7/2 4, Screw the selector lever sleeve nut (6) upwards to such ‘an extent that the locating stop (7] con be removed from the lever (5). Fig. 713 ‘5, Remove shaft screw (8) and withdraw the push button (9) ond gear lever rod (4) from the lever handle (3) Fig. 7/4 7” 72 7. 1 ice god GA 72GA 73 6. A gear shaft lever sleeve nut (6) with flange must be used in order to prevent seizure of the curtain bristles, ot the preselector gate. 7, Moreover, the locating stop (7] must either correspond to the drawing in Fig. 7/5 or be replaced by the new ‘component under part number 16 66 339, Fig. 75 eee eee aes oa SeaTac ene Stal ae Seton tee J. Wanneroo tne ger eco may Spe eer cheba teste | ecmcetoee en 10. The slot of the fork head on the gear lever rod (a) must be located at 90° to the direction of travel Warning: Never turn further in the tightening direction when correcting the position of the fork head. 11, Selector lover shaft sleeve nut (é} fo be screwed down- ward until the distance between the flenge and gear change gate (12) corresponds fo approx. 0.393" (10 mm} Screw on the selector lever handle (3, ig. 78 12, Screw the selector lever handle upwards until the press button (9) can be easily pushed into the fork head of the lever rod (4). Ideally, the head of the push button (9) must lift locating stop (7) af least 0011-0019" (03-05 mm) by means of the roller (13) Fig. 7/9 13, Secure the press button by means of the shaft screw. 14. Chack the selector rod for ease of operation, neGAT/A Fig. 719 1scas 10.15 Removal and installation of the gearbox Tools: Open-ended sponners SW 10, 12, 13; box spanners SW 10, 13, 17; ring sponners SW 13, 17; cranked spanners SW 13; Torque wrench; screwdriver. Special tools: Engine rcising support BMW 600, ratchet BMW 6015. 1. Remove the exhaust pipe from the triangular flange (F) (open-ended sponners SW 12 and 13} 2. Unscrew the exhaust support anchoring bolts (1 ond 2) (box ond open-ended spanners SW 10}. Fig. 3, Detach the exhaust pipe from the manifold flange (box spanner SW 17). When refittn poste threaded studs with Molykote 4 Remove the center-exhaust bracket (box and open- ended spanners SW 13) and tie the exhaust up to the reer drive shaft 5, Remove the speedometer drive securing scrow (2) (openended spanner SW 13) and withdraw the speedo: meter drive (4 4, Detach the propellor shaft (G) at the gearbox (ring and open-ended spanners SW 13) and withdraw towards the rear away from the output flange. 7. Remove the fixing serew (5) of the Bowden cable (b) from the gearbox {open-ended spanner SW 10) Fig. 9 8, Disconnect the selacior rod (1) from the manual gear lever (2 Fig. 10 9. Remove the retaining spring clip (7) from the ball-ioin ‘tthe link rod (8) and disconnect the latter. Fig.11w 10, Detach cables from starter lock and reversing lamp switch When refitting: The two opposed pins furthest aport {8 & 9) should be connected to cables grean/black and green/white, the two pins closer together to cables brown/black and brown. Fig. 12 11, Unscrew steering guide laver bearing bracket securing bolts (SW 13 socket wrench) When refiting: Tighten securing bolts with torque wrench to 25 mkp. (18.1 fb) Fig. 13 12, Tum steering to full right lock. 13, Swivel becring brackst round against bulkhead. Fig. 14 14, Turn steering slightly bock towards straight-chead posi tion and rest steering arm on top of suspension wish bone. Fig. 15 15, Attach engine with engine lifter BMW 600 to the his16, Loosen support bracket securing b wrench) 17, Loosen nut (3) and retaining bolt (2] (socket wrench and ring spanner, SW 13) Fig.16 ) (SW 13 socket 18 Loosen anginelgorbox securing bol (oat wronhas toe ring spanner 3 138 S17) 18. Wihdrow oiler pipe from gearbox Impertnt Owl ecope from the exting operas ] rie inmecttay wah loses sper Fig? 2. Loosen cover plate bolts (SW 10 socket wrench) Fig. 180 21. Loosen the 4 diophrogm (driving disc) securing bolts {cranked ring spenner, SW 13). These con be reached through the hole in the flywheal. To bring the bolts ‘opposite the hole, turn engine with ratchet BMW 6015, When refitting: Tighten the securing bolts with « torque wrench to 20 + 04 mkp. (147 + 2.89 fb) Fig. 186 22, Loasen lateral gearbox support bolts (1 & 2} (socket wrench SW 1”y Pull engine upwards and towards front wih engine Fiting Boom BAW abd ofr moveront of he abbr engine mountings wil allow. Seporote gearbox from engine Werning: The torque convertor must not slip out ofthe gearbox. The torque convertor fs filled with cil Push Back the torque convertor with a screwdh the hols in the fy from the engine When renewing the gearbox the two dowel sleeves must always be renewed alto. If this instruction is ignored the torque convertor and driving dise will be seriously damaged. Fig.21 Unless specific instructions to the contrary ore given, refit in the reverse sequence. All assembly work must be carried out in conditions of the utmost cleanliness. Never use lity rags or cloth to hold or clean parts, only chamois leather. ‘Clean rubber parts with spirit 10.20 Removing and. refitting torque convertor Special tools required: BMW 6028 assembly grips. Remove or refit gearbox (Procedure 10.15) Screw BMW 6028 assembly grips into two holes on ‘opposite sides of the torque convertor. Carefully withdraw torque convertor (2} from convertor dome (5) over the support sheft (4), using BMW 6028 rips. Warning: Do not tilt the torque convertor (2). The driving peg could domage the radial seal. (When refittin Torque convertor for BMW 1800 = colour coded with green spot BMW 2000 = colour coded with white spot Insert torque convertor into half-moon pump, turning slightly meanwhile Warning: Do not damage the radial seal The torque convertor is correcily positioned when the central guide pin does not project beyond the edge of the housing. Fig. 22 Fit testing device 6062. Check torque convertor for leakage ot 0.5 atm. (7.1 psi). Fig. 23 CAN10.21 Renewing driving dise Remove (refi) torque convertor. Remove locking plate (2 Unscrew flywheol securing bolts. When refiting: Tighten securing bolts with torque wrench to 10-1 mkp (723-72 fb) Renew driving dise (I. Fig.2460 Note position of locking plate (2). Fig. 24b 10.25 Renewing input shaft radial seal Special tool required: BMW 6090 sleeve. BMW 6051-1 radicl seal extractor. it) torque convertor (Procedure 10.20), Remove ( Place radial seal extractor. Extract radial seal from oil pump. Fig. 25 Coot the outer shoulder of the new radial seal (2) with « thin leyer of “lzeme" sealing compound, Drive the radial seal (2} into the oil pump with sleeve BMW 6030 (1). Fig. 26 10.30 Removing and refitting oil pump Special tools required: BMW 6002-1 support frome, BMW 4093 driving flenge. Remove (refit) torque convertor (Procedure 10.2) Mount gearbox an BMW 6002-1 support frame, but do not tighten down excessively If caro is net token, gearbox casing may be distorted Unscrew convertor dome retaining nuts), Fig. 27 4] For tightening torgue, see Specification.\ o 5. Loosen convertor dome (1) by striking gently with @ plostiesheaded hammer. 6. Withdraw convertor dome (1} ‘When refiting: Renew gasket (4). The sealing surface must be perfecily clean, Fig. 28 7. Loosen oil pump retaining bolts (10 mm socket wrench) I Important: Hoid oil pump with a screwdriver (1) to prevent it from falling, When refitting: Tighten retaining bolts with @ torque wrench to 1.0 mkp (7.23 Fb). Fig. 29 8, Withdraw oil pump bedy (3) with annulus (é) and pump pinion (6) rom carrier shat (2). Fig. 20 Important: Note installed postion of pump pinion (5), with annular passage facing converter dome. Oil return Passage in pump must coincide with oil roturn drillway in converter dome. Always renew O-ring (6) 9. Fit driving flenge BMW 6023 1) to oil pump and check froodom of movement. Fig. 31 Where no specific instructions to the contrary ore given, installation isto be carried ovt in the reverse sequance. 2.68 Alwation GA 1310.35 Renewal of carrier shaft Tools: Spanners 10, 12, 13 mm, socket wrenches 10, 13, 17 mim, ring spanner 13 mm, cranked ring spanner 13 mm, serewariver, spindle press, hotplate, thermochrome pin. Special tools: BMW 600 engine lifter, BMW 6015 ratchet, BMW 6002-1 support plate, BMW 6028 assembly handgries, BMW 6033 driving flange. Remove (refit) gearbox (Procedure 10.15, Items 1-24) 2. Remove (refit) torque convertor (Procedure 10.25, Items 2-4) 3, Remove (refit) oil pump (Procedure 10.30, Items 3-9} 4. Unscrew carrier shaft bolts (2) from convertor dome (2) (10 mm socket wrench] When refitting: Tighten bolls with torque wrench to LO mkp (7.23 tb} Fig. 32 Press out carrier shalt (2) from dome, us press (1) and a protective sleeve (3) Fig. 33 When refitting: Heat convertor dome to approx. 60°C (140°F] (hotplate, thermachrome pin} Fig. 34 10.40 Gear selector unit ~ removal and refitting Tools: 10 mm socket wranch, 19 mm ring spanner, cirelip pliers, forque wrench. 1. Unscraw drain plug (1) and drain oil (19 mm ring spanner). 2, Unscraw boltsholding oil sump (2) 10mm socket wrench) tand remove sump, When refitting: Tighten holding bolts with torque wrench 10 1.0 mkp (7.23 tl), Fig. 35y Jd wy Warning: From gearbox No. 8460 onwards (arrow), the valve housing and mesh filter have been modified. The ‘existing mesh filter can be fitted to the new valve housing. Fig. 36 Unscrew meth filter retaining bolts (1 end 2)*) Important (only when renewing mesh filter): Tighten retaining bolt to 1.0 mkp (7.23 ft}, loosen and retighten to 0.6 mkp (434 Fl). Fig. 37 Withdraw mesh filter from pipe ond remove from selector unit Warning: When refiting, place sealing ring (4) in the ‘operture on mach filter’ Push sealing ring (5) over vertical pipe. Lerger die. of sealing ring lip faces mesh filter. Loosen bolts) helding selector unit. Fig. 38 Toke off selector unit When rafting: Ensure thot pin (2) of index pawl enters the slot in selector slide (3) Fig.39 4) For tightening torques, see Specification. 9.48 Alteration‘Warning: When fitting new selector unt. Unit has been modified on introduction of selector linkage with reverse motion lever. Maker's cade now 1024 423148 (A) Previous version code 1024 423141 (8 Fig. 3971 aan 7. Apply a compressed air source to inlet drillways 7, 9, 10, 17 brakes are operating correctly. 1. Oil pump pressure outlet measuring point ° 2 Clutch A oil pressure measuring point 10 3 Convertor oil pressure measuring point n 4 Oil pump, oil inlet to pump 2 5 Inlet union, inlet to purip 13 6 Oil pump, oil outlet from pump 7 Clutch A, oil supply Tine to clutch 4 8 Convertor oil supply line to convertor 5 6 cond 12 to confirm thot the multizplate clutches and Clutch B, oil supply line to clutch Brake C;, oil supply line to brake Brake C, el supply line to brake Brake D, cil supply line to broke Gearchange throttle valve pressure, line to measuring point Governor pressure, line from governor to selector unit Oil supply line to governor Governor pressure after governor, measuring pointWw 10.45 Control system layout ©} general crrangement and valve block ppenee: cA5) Pump housing ond throtile pressure housing A Selector unit complete B Pump housing C Throttle pressure valve housing Fig. 43 B Pump housing C Throttle pressure valve housing 1. Locking valve (Ist-2nd gear position} 2. Clutch shock obsorber (clutch 5) 3. Clutch shock absorber spring 1. Locking valve spring oltle pressure valve spring attle pressure valve piston 3 Bush 4, Selactor throttle pressure piston 5, Selector throttle pressure spring 6. Selector throttle pressure valve 7. Main throttle pressure valve Fig. 44 cA IB