To Remove

Gearbox Assembly B284

To remove
1. When changing gearbox, perform Before removing a control module.
2. Place covers over the wings to keep the paintwork clean and protect it from damage.
3. Remove the upper engine cover.





4. Undo the expansion tank cap to release any pressure.

Warning: The cooling system is under pressure. Hot coolant and steam can escape.
^ Open the cap slowly to release the pressure.
^ Carelessness can cause eye and burn injuries

5. Remove the battery cover.
6. Remove the battery.
7. Remove the cable duct, bonnet switch electrical connection and the electrical center from the battery tray. Remove the battery tray.





8. Undo the upper bumper shell mountings.





9. Remove the mass air flow sensor connector.





10. Remove the hose from the secondary air injection pump plus the vacuum hoses.
11. Remove the air filter cover and the hose of the mass air flow sensor.
12. Remove the mass air flow sensor and the hoses of the turbocharger.
13. Suspend two 83 95 212 Strap in place above the radiator core so they are accessible from below.
14. Raise the car.
15. Drain the coolant. See Draining the cooling system.
16. Remove the front wheels.
17. Remove the spoiler shield. CV: Remove Chassis reinforcement, front subframe, CV
18. Secure the radiator core with the straps.
19. Remove the rear catalytic converter.

Important: Take care so as not to crack the flex bellows.




20. Remove the engine torque rod from the subframe.





21. Remove the bolt and nut holding the suspension arm to the steering swivel member on both sides.





22. Unplug the connector and detach the cable clip of the headlamp angle sensor (option)
23. Remove the front part of the wing liner and bend it out of the way.
24. Remove the steering gear from the subframe. Keep the nuts and washers safe. Leave the steering gear hanging.





25. Open the clamps holding the power steering pipe to the subframe.
26. Place 83 95 311 Trolley lift under the vehicle. Fit 83 94 801 Parent fixture, 83 95 188 Basic fixture, 83 95 170 Adapter (4 pcs) and 83 96 137 centering tool, subframe - body.
Position the locating pins and adjust the height of the adapters for even pressure.





27. Remove the subframe bolts and the rear brackets.





28. Lower the subframe slightly.
29. Remove the anti-roll bar from the subframe.
30. Pull out the steering arm ball joints from the steering swivel members.
31. Lower the subframe and move away the trolley lift.
32. Remove the rear torque rod bracket from the gearbox.





33. Remove the front torque rod bracket from the gearbox.





34. Remove the secondary air pump bolts.




35. Remove the air connections from the secondary air pump.
36. Remove the electrical connection and coolant hose from the secondary air pump.
37. Remove the secondary air pump with mounting.





38. Unplug the starter motor electric connections and remove the starter motor.





39. Remove the battery ground cable and wiring harness clamp from the metal bracket.
40. Remove the screw from the coolant pipe attaching lug.
41. Remove the bolts holding the torque converter to the driver plate. Rotate the engine clockwise with the center bolt on the belt pulley.
42. Place a receptacle under the car and drain the transmission fluid. Refit the oil plug with a new seal. Fit also the level plug.

Tightening torque, drain plug 45 Nm (33 ft. lbs.)





43. Detach the transmission oil cooling hoses and plug the holes and hoses with 82 92 955 Plugs, spare part kit
44. Loosen the left-hand drive shaft using 87 92 616 Removal tool, drive shafts.
45. Hang up the shaft with 83 95 212 Strap.
46. Lower the car to the floor.
47. Remove the coolant pipe from the thermostat housing.





48. Unhook the expansion tank from its mounting on the bulkhead wall.





49. Remove the upper heat shield from the catalytic converter.





50. Remove the lower heat shield from the catalytic converter.
51. Remove the turbo delivery hose from the turbo.





52. Remove the cable duct from the gearbox.





53. Pull out the lock pin, press down the lock and unplug the control module connector. Pull up the wiring harness.
54. Remove the gear cable from the selector lever arm.





55. Remove the cable from the cable retainer by pulling back the locking sleeve.
56. Undo the cable from the rear mounting.
57. Remove the gearbox ventilation hose.
58. Remove the upper bolts from the gearbox. Use 32 025 063 Special socket.





59. Fit 83 94 850 Lifting beam and 83 95 287 Holder with 32 025 037 Hook for lifting beam on the engine. Take the weight off the engine and gearbox.





60. Mark the location of the bolts on the left-hand engine bracket with a marker pen for correct refitting and remove the bracket from the gearbox.





61. Lower the power train with the lifting beam to facilitate removal of the transmission.
62. Raise the car and fit 87 92 608 Holder for single-column lift onto a column jack.
63. Adjust and fasten the tool in the gearbox as illustrated. Use the M12 holes for the torque rods.





64. Remove the lower bolts holding the gearbox to the engine and retain the wiring harness mounting at the front bolt.





65. Pull out the gearbox about 10 mm.
66. Undo the plug and press the torque converter towards the transmission and fit 87 92 574 Holder for holding the torque converter in place while removing the transmission.
67. Pull out and let down the gearbox.

Important: The jack can tip over. Be careful.

68. Lift the transmission down from the column jack with an engine lift and 87 92 442 Lifting cable while undoing the lifting tool from the transmission.
69. Plug the holes for the drive shafts if the gearbox is being transported or washed. Use 87 92 665 Protective plug, drive shaft hole.