Gearbox - Td4

JATCO Gearbox - Td4

Remove

1. Disconnect battery earth lead.
2. Tie bonnet back in upright position.
3. Remove intake ducting assembly.
4. Remove fluid cooler.
5. Remove starter motor.
6. Remove IRD.






7. Secure LRT-54-026 to drive shaft inboard joint. Using a suitable lever, release inboard joint from gearbox.
8. With assistance, pull hub outwards and remove LH drive shaft from gearbox.

CAUTION: Pull the drive shaft horizontally to avoid damaging the differential oil seal.






9. Remove and discard circlip from LH drive shaft.






10. Loosen selector cable trunnion nut.
11. Release clip, disconnect selector cable and remove trunnion.






12. Remove bolt securing closing plate to gearbox.
13. Remove grommet from closing plate to gain access to torque converter retaining bolts.






14. Mark drive plate to torque converter, for refit purposes.
15. Rotate crankshaft for access and remove 4 bolts securing drive plate to torque converter.






16. Remove bolt and release earth lead from gearbox.






17. Loosen clip and disconnect hose from turbocharger outlet pipe.






18. Release 2 gearbox multiplugs from clips and disconnect from main harness.






19. Fit lifting chains to lifting eye and take weight of engine.






20. Remove through bolt, gearbox bracket to LH mounting.
21. Lower gearbox to clear mounting.






22. Remove 4 bolts securing LH mounting bracket to gearbox and remove bracket.






23. Fit lifting eyes to gearbox and secure with bolts.
24. Fit lifting chains to eye and take weight of gearbox.






25. Remove 2 bolts securing gearbox to engine.






26. Remove lower bolt securing gearbox.






27. Remove 2 upper bolts securing gearbox to engine.
28. Release gearbox from 2 dowels.
29. Manoeuvre and lower gearbox to floor.






30. If necessary remove displaced gearbox closing panel.






31. Fit converter retaining plate and secure with bolts.

Refit

1. Clean gearbox closing panel.
2. Ensure closing plate is in position on engine and located on dowels.
3. Clean drive plate and ensure free from cracks and distortion.
4. Clean gearbox to engine mating faces, dowels and dowel holes.
5. Remove torque converter retaining plate.
6. Ensure torque converter is fully located in oil pump drive by checking depth 'A' as illustrated. Depth A = 27 mm.
7. Fit lifting chains to eyes and take weight of gearbox.
8. Raise gearbox and engage with dowels. Fit bolts securing gearbox to engine and tighten to 85 Nm (63 lbf.ft).
9. Fit bolt securing closing plate to gearbox and tighten to 10 Nm (7.5 lbf.ft).
10. Remove lifting chains from gearbox.
11. Fit mounting bracket to gearbox and tighten bolts to 85 Nm (63 lbf.ft).
12. Raise engine, align bracket to mounting and tighten through bolt to 100 Nm (74 lbf.ft).
13. Remove engine support chains.
14. Align torque converter to drive plate and tighten bolts to 45 Nm (33 lbf.ft).
15. Fit grommet to access plate.
16. Fit trunnion to selector lever, fit inner cable to trunnion and secure outer cable to abutment bracket.
17. Adjust selector cable.
18. Connect gearbox harness multiplugs and fit to clips.
19. Position earth lead to gearbox and tighten bolt to 25 Nm (18 lbf.ft).
20. Connect intercooler hose and tighten clip.
21. Fit new circlip to LH drive shaft.
22. With assistance, fit LH drive shaft to gearbox, keep shaft square to prevent damage to oil seal in gearbox.
23. Fit IRD.
24. Fit starter motor.
25. Fit fluid cooler.
26. Fit intake ducting assembly.
27. Connect battery earth lead.
28. Untie and close bonnet.