Transmission, Installing

Transmission, installing, 02E, 6 Speed Direct Shift A/T, AWD
Perform installation in reverse sequence of removal. Note the following:

Note:
^ Secure all hose connections with the correct hose clamps (as original equipment).
^ Replace gaskets and seals.





- Before installing, ensure that dowel sleeves - A - are correctly seated in cylinder block.
A: Dowel sleeves for aligning
- Before installing transmission, check needle bearing in crankshaft.





To install the direct shift transmission 02E the transmission support 3282 is set up together with the adjustment plate 3282/42.
- Align arms of transmission support according to holes in adjustment plate.
- Bolt support elements as illustrated to adjustment plate 3282/42.
- Place transmission jack under vehicle; arrow symbol on adjustment plate points in direction of travel/to front of vehicle.
- Align adjustment plate parallel with transmission.
- Secure support element to transmission using bolt - 1 -.
- Screw support element 3282/29 into transmission.
- Insert support element - 2 - into transmission and secure by tightening nut.
- Raise transmission carefully and move to installation position using transmission support 3282.
- Insert transmission and make sure no wires or hoses become pinched or caught.
- Install all securing bolts for engine/transmission assembly.





- Carefully press selector lever cable onto selector shaft lever on transmission in opposite direction of arrow.
- Install circlip - A - and press downward to secure.

Note: Do not kink selector lever cable.





Install the assembly mounting as follows:
- Place transmission support - A - between transmission and transmission mounting.
- Pull transmission up to transmission mounting with spindle on support bracket.

CAUTION! Before tightening bolts between the transmission mounting and the transmission support, the mounting and support must be aligned in an absolutely parallel position, otherwise the threads will be damaged. If necessary, push the transmission up at the rear with a trolley jack.





^ Transmission support - A - to transmission
- Replace bolts.








Transmission support to transmission mounting - arrows -.
- Replace bolts.
- Initially tighten bolts finger-tight, then tighten to specified torque.





CAUTION! Only remove support bracket 10 - 222 A after all bolts for the assembly mounting are tightened to specified torque and the subframe is installed.





- Screw in securing bolts - 1 - and - 2 - at bracket for bevel box finger-tight.
- Secure bracket for bevel box; note following assembly sequence:
- Screw in all bolts finger-tight.
- Tighten bolts - arrow1 - initially to 3 Nm.
- Tighten bolts - arrow2 - to 35 Nm.
- Tighten bolts - arrow1 - to 45 Nm.





- Replace bolts - 1 -.
- Secure support bracket - D - together with selector lever cable to transmission.





^ Do not kink selector lever cable.





- Install subframe.





- Screw on pendulum support at transmission - arrows B -.
- Replace bolts.
- Press engine/transmission assembly toward bulkhead. Bevel box pin must be guided carefully into driveshaft flange when doing this.





Note:
^ When removing and installing, do not damage the seals in the driveshaft flanges. If the seals are damaged, the driveshaft must be replaced.
^ Ensure the driveshaft is horizontal when pushing it onto the guide pin.





- Use new bolts and screw on pendulum support at subframe - arrows A -.





- Bolt driveshaft with flexible coupling to bevel box flange - arrows -.





Note: Take note of the markings that were made on the driveshaft and flange when removing. These must align with each other again - arrows -.

- Assemble exhaust system.
- Install heat shield for axle shaft (right side) and tighten bolts to a torque of 25 Nm.
- Install axle shafts.





- If equipped, install bracket for headlight range control in wheel-housing (left side) - arrows -.





- Install bracket - A - (bolts - 1 - and - 2 -).

Note: Bracket - A - is secured to front of engine oil pan.





- Secure bracket - A - using nut - 1 - to front cover of transmission.
- Install battery.
- Follow steps required after connecting battery.
- Assemble exhaust system free of stress.
- Check transmission oil level and top up if necessary.
- Check selector lever cable setting and adjust if necessary.
- Check coolant level in cooling system.