Gearbox - KV6- with Engine and Gearbox Removed

Remove





1. Release H02S multiplug from support bracket on LH camshaft cover, disconnect multiplug.





2. Remove 4 nuts securing LH exhaust manifold to cylinder head.
3. Remove exhaust manifold, remove and discard gasket.





4. Remove nut securing manifold heat shield to IRD unit.
5. Remove nut securing heat shield to IRD pinion housing.
6. Remove 2 bolts securing heat shield and remove heat shield.





7. Disconnect breather hose from IRD housing.





8. Release clips and disconnect coolant hoses from IRD.





9. Remove bolt securing engine lower steady to IRD support bracket.
10. Remove lower engine steady noting that 'TOP' mark on engine steady faces uppermost.





11. Remove 3 bolts securing IRD support bracket to sump.





12. Remove 2 bolts securing IRD support bracket to engine front mounting plate.





13. Remove 5 bolts securing support bracket to IRD.
14. Remove support bracket.





15. Remove 4 bolts securing IRD.
16. With assistance, release IRD from gearbox end remove.





17. Remove and discard 'O' ring from IRD.





18. Remove 2 bolts securing torque converter access plate.
19. Remove access plate.
20. Mark drive plate to torque converter, for refit purposes.





21. Remove 4 bolts securing drive plate to converter.





22. Remove bolt securing IRD cooling hose retainer. Remove retainer.





23. Remove bolts securing LRT-44-026 lifting bracket to gearbox and remove bracket.





24. Remove 3 bolts securing starter motor to gearbox noting that the LH bolt also secures the mounting bracket for the CKP sensor multiplug.
25. Remove starter motor.





26. Disconnect 2 fluid cooler hose unions and discard 'O' rings.

CAUTION: Always fit plugs to open connections to prevent contamination.





27. Release 2 clips and disconnect coolant hoses from fluid cooler.





28. Remove bolts securing fluid cooler.
29. Remove fluid cooler.





30. Remove bolt securing CKP sensor to gearbox, release sensor and position aside.
31. Remove nut and bolt, adjacent to CKP sensor, securing gearbox to engine.
32. Fit suitable lifting brackets to gearbox and secure with nuts and bolts.
33. Connect lifting equipment to brackets.





34. Remove 2 bolts securing gearbox to engine.





35. Remove 2 top bolts securing gearbox to engine.
36. Release gearbox from 2 dowels.
37. Remove gearbox assembly.





38. Fit converter retaining plate and secure with bolts.

Refit
1. Remove torque converter retaining plate.





2. Ensure converter is fully located in oil pump drive by checking depth 'A' as illustrated. Depth A = 4 mm.
3. Clean gearbox to engine mating faces, dowels and dowel holes.
4. Fit gearbox assembly.
5. Fit bolts securing gearbox and tighten to 85 Nm (63 ft. lbs.).
6. Disconnect lifting equipment.
7. Clean CKP sensor and mating face.
8. Fit CKP sensor, fit bolt and tighten to 9 Nm (7 ft. lbs.).
9. Position fluid cooler, tighten M12 bolts to 85 Nm (63 ft. lbs.) and M8 bolt to 25 Nm (18 ft. lbs.).
10. Connect hoses to fluid cooler.
11. Clean fluid cooler unions.
12. Lubricate new 'O' rings with clean transmission fluid and fit 'O' rings to fluid cooler hoses.
13. Connect fluid cooler hoses to gearbox and tighten unions to 18 Nm (13 ft. lbs.).
14. Clean starter motor mating faces.
15. Position starter motor to gearbox, align CKP sensor multiplug bracket, fit and tighten bolts to 45 Nm (33 ft. lbs.).
16. Using gearbox bracket bolts, secure LRT-44026 lifting bracket to gearbox.
17. Position IRD cooling hose retainer, fit bolt and tighten to 25 Nm (18 ft. lbs.).
18. Align marks on drive plate to torque converter.
19. Fit bolts securing ring drive plate to torque converter and tighten bolts to 45 Nm (33 ft. lbs.).
20. Clean torque converter access plate.
21. Position access plate, fit bolts and tighten to 9 Nm (7 ft. lbs.).
22. Clean mating faces of IRD and gearbox.
23. Lubricate and fit new 'O' ring.
24. With assistance, fit IRD.
25. Fit bolts securing IRD to gearbox and tighten sufficiently only to pull mating faces of IRD and gearbox together at this stage.
26. Fit IRD support bracket and tighten bolts sufficiently only to pull mating faces together.
27. Final tighten bolts securing IRD to gearbox to 80 Nm (59 ft. lbs.).
28. Final tighten bolts securing IRD support bracket in following sequence: 5 bolts securing support bracket to IRD 50 Nm (37 ft. lbs.), 2 bolts securing support bracket to engine front mounting bracket 50 Nm (37 ft. lbs.), 3 bolts securing support bracket to sump 45 Nm (33 ft. lbs.).
29. Position lower engine steady, 'TOP' mark uppermost. Fit bolt but do not tighten at this stage.
30. Connect coolant hoses and secure with clips.
31. Connect breather hose to IRD housing.
32. Fit manifold heat shield and fit nut securing heat shield to pinion housing finger tight.
33. Fit bolts securing manifold heat shield to IRD support bracket and tighten to 9 Nm (7 ft. lbs.).
34. Fit nut securing heat shield to IRD and tighten to 45 Nm (33 ft. lbs.).
35. Final tighten nut securing manifold heat shield to IRD pinion housing to 25 Nm (18 ft. lbs.).
36. Clean exhaust manifold and mating face on cylinder head.
37. Fit exhaust manifold gasket.
38. Position exhaust manifold, fit nuts and progressively tighten, from center outwards to 45 Nm (33 ft. lbs.).
39. Connect HO2S multiplug and secure to support bracket.