24 00 033 Removing and Installing Automatic Transmission (GA8HP45Z)

24 00 033 Removing and installing automatic transmission (GA8HP45Z)

Special tools required:







IMPORTANT:
- Do not let skin come in contact with transmission oil and do not inhale transmission oil vapours.
- Wear protective gloves.
- Ensure adequate ventilation







IMPORTANT:
After completion of work, check transmission oil level.
Use only the approved transmission oil.
Failure to comply with this requirement will result in serious damage to the automatic transmission.







IMPORTANT:
Aluminium screws/bolts must be replaced each time they are released.
Aluminium screws/bolts are permitted with and without colour coding (blue).
For reliable identification:
Aluminium screws/bolts are not magnetic.
Jointing torque and angle of rotation must be observed without fail (risk of damage).







Necessary preliminary tasks:
- Disconnect the battery
- Release the left and right charge air hoses from the charge air cooler
- Remove front underbody protection
- Remove reinforcement plate
Important installation notes are described in this job item
- Remove propeller shaft
- Release monitoring sensor on catalytic converter
- Support engine with jack when removing transmission







Remove upper part of cable duct (1).







Unfasten ground strap (1).
Remove retaining plates (2).







Release cable (1) from holder (2).







Release screw (1).
Disconnect hydraulic lines (2) to transmission oil cooler.
Tightening torque 17 22 1AZ.

Installation note:
Replace sealing rings.
Note installation position.

IMPORTANT:
Keep to installation sequence.
Failure to observe this sequence will result in leaks.
- 1. Lower hydraulic line.
- 2. Upper hydraulic line.







Release coolant hose (1) from holder (2) and lay to one side.







Crank engine at vibration damper in direction of rotation until screw (1) is visible in recess.
Release all 6 bolts of torque converter with special tool 24 1 110.

Installation note:
Replace converter screws. Remove any remaining adhesive residue from the thread.
Tightening torque 24 40 1AZ.







Release nuts (1) and (2).
Tightening torque 18 20 1AZ.







Release screws (3), (4) and (9).

NOTE: Aluminium screws must be replaced.

Tightening torque 24 00 2AZ.







Prepare special tool (1) 24 4 161 (A) with shaped element (2) 24 4 166 as pictured.







Insert special tool 24 4 160 into recess of transmission housing and clamp gently with screw (1).
Raise by turning screw (2) and clamp down.
Then tighten down screw (1).







- Unlock and disconnect connector (1) by turning.
- Do not touch pins.
- Release cable from brackets.
- Insert special tool 24 2 390 in sealing sleeve.

Repair work is described in
Notes on mechatronics

IMPORTANT: Read and comply with important note.







Release screw (1) on left and right of axle.
Remove cover plate (2) on left and right of axle.
Remove bolt (3) on left and right of axle.
Tightening torque 31 10 1AZ.







Screw on special tool 11 8 910.







Adjust distance (1) between cross bar and facing using nuts (2).
Nuts (2) must be screwed down in opposite direction after distance has been adjusted.

IMPORTANT:
Distance:
N55 38.5 mm







Supporting transmission:
Support transmission with special tools 23 4 050,00 2 030.
Secure transmission to mounting with tensioning strap (1).
Tasks are described in Gearbox holder.
After completion of work, check transmission fluid level.







Unscrew nut (1) and bolts (2).
Remove gearbox cross member (3).
Tightening torque 22 32 3/4AZ.







Release screws.
Remove exhaust system holder.

Installation note:
Observe screw fastening sequence without fail.
Tightening torque, steel screws 24 00 1AZ.
Aluminium screws must be replaced.
Tightening torque and angle of rotation, aluminium screws/bolts 24 00 2AZ (7, 8, 9, 10, 11).







Installation note:
Tighten down screws/bolts to specified torque.

Attach special tool 00 9 120 for angle of rotation with magnet 00 9 130 to vehicle underbody and screw down blue aluminium screws/bolts in accordance with angle of rotation.
Angle of rotation 24 00 2AZ.







Installation note:
Bore hole (1) of drive plate must be accessible from recess on engine oil sump.
Check fitting sleeves (2...3) for correct seating.
Replace damaged fitting sleeves.

NOTE: Graphic representation similar.







Installation note:
Rotate torque converter until bore hole in torque converter is flush with bore hole in drive plate.
Flange automatic transmission to engine.