Removal and Installation

Removing and installing automatic transmission (A4S 270R/310R)

Caution: On vehicles with ASC+T, the throttle body (ASC+T) and/or the expansion tank on the master brake cylinder can become damaged when the transmission is lowered.

Remove throttle body (ASC+T), refer to Powertrain Management.
Disconnect battery.
Removing complete exhaust system.





Engine M51:
Remove splash guards at front, middle and rear.
Remove heat shield (1).





Version with Oil Filler Pipe:
Drain off fluid.

Caution: Never reuse drained oil.

Caution: Clean oil cooler and pipes with compressed air and flush twice with ATF if the transmission is faulty.





Remove clamp (2).

Installation:
Install holder with long shoulder (3) facing forward.





Loosen screwed-on ring (1) several turns.

Installation:
After installation, tighten screwed-on ring (1) with special tool 26 1 040.
Tightening torque, refer to Automatic Transmission/Transaxle, Specifications.





Unscrew propeller shaft on transmission.

Installation:
Replace self-locking nuts.
Tightening torque, refer to Automatic Transmission/Transaxle, Specifications.





Version with joint disc, front:
Unscrew joint disk on transmission.





Installation:
Replace stop nuts.
Tightening torque, refer to Automatic Transmission/Transaxle, Specifications.
To prevent torsion stress on the joint disc, only turn the nuts or bolts on the flange side - if possible.





Unscrew centre mount.

Installation:
Preload center mount in forward direction (A) 4 - 6 mm.
Tightening torque, refer to Automatic Transmission/Transaxle, Specifications.





Pull the propeller shaft downward at the centre bearing pulling it off the centering pin on the manual transmission.

Caution: Do not let propeller shaft fall into joints. This would squash the rubber gaiter, especially on the constant velocity joint.





Unfasten nut (1) in setting "P".

Caution: Always brace bolt with special tool 24 5 210 to avoid deformation of the cable.

Special tool 24 5 210 can only be fitted in position "P".
Tightening torque, refer to Automatic Transmission/Transaxle, Specifications.
Unscrew cable from holder.
Pull out cable.
Tightening torque, refer to Automatic Transmission/Transaxle, Specifications.

Installation:
Adjusting shift mechanism, refer to Shift Linkage A/T, Adjustment.





Turn bayonet lock (1) counterclockwise.
Pull off plug (2).
Lift wire harness out of holder.

Installation:
Connect plug (2) that marks are aligned.





Pull plug (1) off speed sender.





Lift off cover from opening (1) on side of crankcase.
Using special socket 24 1 110, release three screws securing torque converter to drive flange.
Turn flywheel for this step.





Installation:
Install screw, using special socket 24 1 110.
Tightening torque, refer to Automatic Transmission/Transaxle, Specifications.

Caution: Only use original bolts.





Engine M40:
Removing air collection box.
Unscrew cable duct from rear end of engine.
Support engine at rear end before unscrewing cross member.
Mount special tool 00 0 200 and hook it into the eye on the crankcase.
Tighten spindle (1).





Engine M51:
Remove cover from manifold.
Secure special tool 11 2 370 on intake pipe, rear.
Assemble special tool 00 0 200 and attach to special tool 11 2 370.
Tighten spindle.





Engine M43:
Attach special tool 11 8 022.





All:
Preassemble special tool 24 5 300 (fixture) to suit transmission THM-R1 as marked.





Support transmission with special tool 24 5 300 (fixture in conjunction with special tool 00 2 020 (lifting fixture).





Remove cross tube.





Remove cross member with rubber mounts.

Installation:
Centering transmission.
Tightening torque, refer to Automatic Transmission/Transaxle, Specifications.
Lower transmission, until the cylinder head or manifold no longer abuts the engine fire wall or the heating connections (visual inspection).





Engine M43:
Fit carrier of special tool 11 8 022 firmly with knurled screws on oil pan.
(This special tool prevents the engine from tilting backwards when the transmission is removed).





All:
Release oil cooler pipe clamps from crankcase and oil pan.





Unscrew front oil cooler pipe.

Installation:
Check O-ring (1), replacing if necessary.
Tightening torque, refer to Automatic Transmission/Transaxle, Specifications.





Unscrew rear oil cooler pipe.

Installation:
Check seals, replacing if necessary.
Tightening torque, refer to Automatic Transmission/Transaxle, Specifications.





Unscrew transmission on engine (Torx screws).





Installation:
Check that washers are fitted to Torx screws.
Tightening torque, refer to Automatic Transmission/Transaxle, Specifications.





Secure converter from slipping by fitting and securing tool 24 4 080 to transmission housing with flat side of retaining element (1) facing converter.
Pull transmission off engine.

Caution: A lifting fixture with mounted transmission may be moved only in completely lowered position.





Check that dowel sleeves (1 and 2) are not missing.
If necessary convert or replace dowel sleeves. Ensure correct position of cover plate.

Installation:
Check drive plate for breaks and cracks, replacing if necessary.





Engine M50:
Version with Sheet Metal Flywheel (2):

Caution: Keep to sequence of installation. Sheet metal flywheel (2) has three indentations for the torque converter mounting tabs.

When guiding the engine and transmission together the three mounting tabs on the torque converter must be aligned with the three indentations in the sheet metal flywheel. Non-conformance leads to follow-up damage on the automatic transmission.
Turning on the torque converter, or engine, is no longer possible after guiding the engine and transmission together and would lead to damage.





Turn the torque converter on the transmission until bore (1) faces down perpendicular to the tab. Screw special tool 24 2 300 into the tab.





Bore (3) on drive plate must point perpendicularly to centre of opening in oil sump.





Lift automatic transmission until bore (3) in drive plate is reached.
Guide transmission in carefully with special tool 24 2 300 in bore (3) on the drive plate.
Bolt transmission housing to engine.
Unscrew special tool 24 2 300 from the tab towards the front.
Mount torque converter.





All:
After the transmission has been refitted, the oil level must be checked and topped up if necessary.

Versions with oil filler pipe:
Take out oil dipstick.

Caution: Oil dipstick has detent.

Tilt handle to unlock oil dipstick for removal.
Run engine in selector lever setting "P" or "N".
Car must be unloaded and stationary on a level surface Interrogate ATF temperature with Service Tester or MoDiC.





Take out oil dipstick and measure ATF level.





Compare measured level with values in the table. Never wipe off oil dipstick with a cloth which loses lint.





Top up ATF only using special tool 24 0 080.

Version without oil filler pipe:
Oil filler pipe was discontinued as of 2.91.
Replenish ATF through filler opening on underside of of pan.





Check the actual level, and top up if necessary.
Car must be unloaded and stationary on a level surface
Only check oil level at a transmission oil temperature of 30 - 55°C.
Interrogate ATF temperature with Service Tester or MoDiC.
Run engine in selector lever setting "P" or "N".
Unscrew filler plug (1).





Allow too much oil to escape or top up with insufficient oil.
To top up ATF, attach filler neck (2) to filler aperture.
Add ATF until it runs out. Screw in and tighten filler plug.

Installation:
Check sealing ring, replacing if necessary.
Tightening torque, refer to Automatic Transmission/Transaxle, Specifications.
ATF level too high
Strong foaming, loss through splashing, high temperatures at high speeds.
Oil lost through vent.

ATF level too low:
Rattling of valves, foaming, spinning of engine.
General malfunction.