Transmission, Installing

Transmission, installing (vehicles with 4.2 ltr. MPI engine), 09L, 6 Spd. A/T AWD

Note:
^ Re-attach all cable ties at the same locations when re-installing.
^ Secure all hose connections with the correct hose clips (as original equipment); refer to Parts catalog.
^ Re-attach heat shield sleeves at the same locations when re-installing.
^ Replace self-locking nuts.





- Before installing transmission, make sure that the torque converter is properly installed in transmission.
^ If torque converter is correctly installed, the depth between contact surfaces at tapped holes on torque converter and contact surface of torque converter bell housing is at least 19 mm.

CAUTION: If the torque converter is not installed correctly, the torque converter drive lugs or the ATF pump will be seriously damaged when the transmission is joined to the engine.





- Before installing transmission, check for correct positioning of dowel sleeves - A - at cylinder block. Install new dowel sleeves if necessary.
- If an intermediate plate was installed between engine and transmission, reinstall plate in same position.
- When pushing engine and transmission together, make sure that no cables, lines, etc. can become trapped.

CAUTION: Before and while tightening the bolts on the engine/transmission flange keep checking that the torque converter can still be rotated behind the drive plate. If the converter cannot be turned, it must be assumed that it has not been installed correctly and the drive lugs on the converter or the ATF pump will be damaged when the bolts are fully tightened.

- Bolt transmission onto engine.
- Use new ribbed bolts to secure torque converter to drive plate. Use only correct bolts (same as original equipment) Parts catalog.





- Insert guide pin of adapter T40058 so that the large diameter - arrow 1 - faces engine. The smaller diameter - arrow 2 - faces adapter.
- Counter-hold crankshaft using adapter T40058 to secure torque converter bolts.





- Install 3 torque converter bolts through opening for starter (finger-tight). Turn crankshaft 1/3 of a turn to access one bolt after another.
- Tighten torque converter bolts to torque (turning crankshaft 1/3 turn each time).





- Insert engine speed (RPM) sensor G28 - item A - into bell housing (top left) and tighten bolt - 1 -.
- Install heat shield - B - and tighten bolt - 2 - (transmission/engine bolt connection)





- Insert ATF cooling lines - A - and - B - into transmission as far as possible and tighten bolt - 2 -.





- Press selector lever cable - 1 - onto selector shaft lever - 3 -.
- Install starter.
- Install transmission support with transmission mounting.
- Install front exhaust pipes.





If measurement performed with locating pin 3393 during removal showed that holes - 1 - and - 2 - were aligned:
- Install subframe, observing tightening sequence.
If measurement performed with locating pin 3393 during removal showed that holes - 1 - and - 2 - were NOT aligned:
- Only tighten bolts for subframe to tightening torque setting, do not yet turn further (wait until wheel alignment has been carried out).

CAUTION: The vehicle must not be driven.

- Clean ATF lines and ATF cooler.
- Secure ATF lines to transmission and engine.





- Bolt on support bracket for selector lever cable - arrows -.
- Secure driveshaft to transmission.





- Secure heat shield - A - for driveshaft - arrows -.
- Install exhaust system free of stress.
- Bolt drive axles to flange shafts.





- Install heat shields - arrow - for drive axles (left and right).
- Adjust selector lever cable.
- Check oil level in final drive (front).
- Check oil level in transfer gear.
- Follow steps required after connecting battery.
- Check ATF level.
- If necessary, carry out wheel alignment.

CAUTION: After wheel alignment tighten subframe bolts to their final torque setting.

Tightening torques

Note:
^ Tightening torques only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
^ Lubricants such as engine or transmission oil may be used, but do not use graphite lubricant.
^ Do not use parts which have been degreased.








Illustration of transmission flange

A: dowel sleeves for centralizing

Securing engine to transmission:





Securing transmission to engine: