4T65 Transmission
Transaxle, removing
Special tools:
998 5972 JACK 998 5972 Jack
999 5045 COMPRESSION HOOK 999 5045 Compression Hook
999 5259 SEPARATOR 999 5259 Separator
999 5395 REMOVAL TOOL 999 5395 Removal Tool
999 5460 Lifting hook 999 5460 Lifting Hook
999 5463 FIXTURE 999 5463 Fixture
999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket
999 5716 Reading off tool 999 5716 Reading Off Tool
999 7018 Lifting lug 999 7018 Lifting Lug
999 5734 Counterhold 999 5734 Counterhold
999 5735 Fixture 999 5735 Fixture
999 5736 Wrenches 999 5736 Wrenches
999 5972 FIXTURE 999 5972 Fixture
999 7077 Jimmy bar 999 7077 Jimmy Bar
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.
Filling in Diagnostic and Check lists
Note! Before replacing the gearbox, fill in the diagnostics/checklist and enclose in the returns box.
Refer to: Diagnostics/check list, B5254T2, AW50/51 AWD, B5254T2, AW55-50/51SN Diagnostics Check List
Caution! Check for coolant in oil Checking for coolant in the oil, AW55-50/51SN, AW50/51 AWD, 4T65EV-GT Checking For Coolant In the Oil and check for metal particles in the oil pan before installing new transaxle. See the end of the method.
Disconnecting the battery lead
See Battery, disconnecting Battery Disconnecting. It is essential that the instructions are followed.
Exposing the lower steering shaft
Set the front wheels to the straight ahead position. Lock the steering wheel.
Remove the upper screw on the lower steering shaft
Expose the lower steering shaft from the upper steering shaft
Press up the upper steering shaft slightly for better access.
Removing engine compartment components
Remove the air cleaner (ACL) housing
See Brake pipe master cylinder / ABS unit, replacing Brake Pipe Master Cylinder / ABS Unit, Replacing.
Applies only to turbo cars:
Carefully heat around the pipe at the charge air cooler (CAC). Use a hot air gun. Loosen and remove the pipe.
Remove the upper torque rod. Remove the screw for the oil hose clamp on the cross member mounting (right-hand side)
See Brake fluid reservoir, replacing, L.H.D Brake Fluid Reservoir, Replacing, L.H.D.
Remove:
- the plastic covers over the spring strut mountings (applies only to early versions)
- the screws
- the screw and nut for the engine mounting.
Removing the charge air hose and the hose clamp (turbocharged cars)
Undo the hose clamp at the twin pipe.
Remove the hose from the twin pipe.
Removing the gearbox cable from its mounting and the lever on the transaxle
Use jimmy bar 999 7077 Jimmy bar 999 7077 Jimmy Bar to detach the ball joint for the gear selector cable from the lever.
Remove:
- the gear selector cable from the bracket. Press the catch under the gear selector cable. Pull the gear selector cable out of the bracket
- the connector from the transmission (press the connector together). Pull it from the transaxle.
Hint: Hang the gear selector cable from a tie strap around the brake pipes.
Removing the hose for the heater pipe
Disconnect the hose from the heater pipes at the firewall so that the pipe in the heater unit is not damaged when lowering the engine (the rubber hose is short).
Twist the catch (see the arrow) on the hose connection. Pull the quick-release connector straight out. A small amount of water should run out (tie the hose up).
Disconnect the ground strip (applies to older models).
Collecting transmission fluid
Remove the dipstick from the dip stick pipe.
Suck up the oil using an oil suction device.
Note! The above must be carried out because the oil flows out of the transaxle when the oil pipe is removed.
Remove the screw for the dip stick pipe by the engine mounting.
Removing the screw from the sub-frame
Slacken off the screw for the clamp holding the oil pipe to the power steering.
Removing the boost pressure pipe
Slacken off the upper screw for the dip stick pipe.
- Slacken off the screw for the clamp around the turbocharger pipe
- Open the clamp so that it is released from the turbocharger (TC)
- Pull the turbocharger pipe from the turbocharger (TC) (push the pipe to one side).
Removing engine compartment components
Remove:
- the lower screw for the dip stick pipe
- the nut for the engine pad (ensure the nut is close at hand when installing the engine pad)
- the screw for the splash guard plate (by the engine mounting).
Cut off the 4 tie straps holding the cable harness on the bracket.
Disconnect the speed sensor connector.
Removing the dipstick
Pull the pipe straight upward out of the transaxle. Ensure that the O-ring stays in place on the pipe.
Installing the lifting fixture
Install fixture 999 7018 Lifting lug 999 7018 Lifting Lug on the left hand side of the engine at the 2 screws.
Lock the fixture using the catch.
Removing the screws for the transmission and starter motor and the ground lead
Remove:
- the 3 screws for the transaxle/engine
- the screw for the ignition setting sender (lift up the ignition setting sender)
- the 2 screws for the starter motor. Remove the starter motor
- the ground lead screw under the starter motor
- the screw for the clamp holding the positive cable on the engine.
Tie the hoses and the cable harness to the intake manifold.
Removing components from the starter motor
Remove:
- the nut for the positive cable and the switch on the starter motor
- the screw at the bracket for the starter motor
Hint: Applies to turbocharged engines: Use a ratchet spanner when removing the screw at the bracket for the starter motor.
Removing the screws from the torque converter
Alternative 1
Installing twisting tool 999 5395 REMOVAL TOOL 999 5395 Removal Tool.
Turn the engine until the screws can be removed. Use a Torx tool (TX50).
Alternative 2
Slacken off and remove the screws in the cut-out between the engine and the transaxle from below.
Turn the engine using a screwdriver in the cut-out under the transaxle.
Installing the lifting beam and lifting hook on the engine lifting eyelet
Note! Position the stand for lifting beam 999 5716 Reading off tool 999 5716 Reading Off Tool on the upper wheel arch members.
Then position the lifting beam directly above the engine lifting eyes on both sides.
Connect lifting hook 999 5460 Lifting hook 999 5460 Lifting Hook. Tighten to light contact.
Disconnecting the front suspension components
Raise the car
Note! Position the front lift arms so that they do not obstruct the sub-frame support plates.
Remove:
- the front wheels
- the splash guard under the engine
- both the screws for the front splash guard. Remove the cover: Press in the catches at the front edge of the cover. Pull the cover backwards.
Removing the screws for the cable conduit and ground lead bracket on the sub-frame
Remove:
- the screw for the front engine pad (see the arrow)
- the screw for the torque rod in the transaxle.
Note! Cars with parking heaters: Remove the nuts for the heater from the sub-frame. Hang the heater on the left front wing.
Removing the nut from the ball joint (both sides)
See Ball joint, replacing Service and Repair.
Removing the control arms for the anti-roll bar, the track rod and the screw from the drive shaft on both sides
Remove:
- link for anti-roll bar up on the spring strut (only left-hand side). Hold with Torx 30. Do not twist rubber boot.
- The screw for the drive shaft.
Removing the screws from the sub-frame support plates (both sides)
Preparations for removal of the wheel knuckle
- Position transmission jack (applied lightly) under the right-hand side of the sub-frame. 998 5972 JACK 998 5972 Jack
- Slacken off both the sub-frame screws completely. Screw the screws back in approximately 5 turns.
- Release the sub-frame so that it rests on the screws and the mobile jack.
Removing stub axle from the control arm
Pry the control arm down.999 7076 Lever 999 7076 Lever At the same time, lift the wheel knuckle off the control arm.
Note! Install socket on the wheel knuckle ball joint. Do not damage the rubber bellow for the ball joint.
999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket
Pressing up the sub-frame on the right-hand side
Press up the sub-frame on the right-hand side.
Tighten the sub-frame screws. Tighten to light contact.
Then slacken off the screws approx. 4-5 turns.
Note! This is because the sub-frame hangs down more on one side.
Move the mobile jack to the left hand side.
Removing the driveshaft from the wheel knuckle (right-hand side)
Grip the driveshaft.
Pull it down towards the control arm so that it tensions.
Pull the brake disc outwards.
At the same time, pull the joint housing towards the transaxle so that the driveshaft releases.
Allow the drive shaft to lie on the control arm.
Removing the cap for the drive shaft support bearing
Remove the screws for the bearing cap.
Unhook the servo pipe and the evaporator pipe from the holders on the right-hand side of the sub-frame. Unhook the servo pipe from the clip on the sub-frame.
Removing the drive shaft
See Half shaft, left, replacing Half Shaft, Left, Replacing and Drive shaft right, replacing Drive Shaft Right, Replacing
Removing the drive shaft from the viscous coupling
Use jimmy bar 999 5395 REMOVAL TOOL 999 5395 Removal Tool.
Position the tool between the drive shaft and the viscous coupling.
Gently tap the tool so that the drive shaft is released from the viscous coupling.
Note! Remove the drive shaft first.
Remove the viscous coupling from the transaxle.
Note! There will be a little oil left in the viscous coupling.
Removing the nuts and screws for the steering gear sub-frame
Remove the nuts and the screws from the steering gear sub-frame.
Removing the front cross member
Drill out the pop rivets for the heat deflector.
Remove:
- the 4 screws by the front cross member
- the screws for the exhaust pipe mounting in the front cross member
- the brake pipe from its holder in the member.
Removing the centre and rear cross members
Slacken off the screws for the cross members.
Remove the 2 screws for each member. Let them hang down.
Removing the bracket for the heated oxygen sensor (HO2S) wiring
Remove the screws for the bracket in the sub-frame holding the heated oxygen sensor (HO2S) cable. Push the bracket to one side.
Disconnect the connectors from the sub-frame.
Disconnect the heated oxygen sensor (HO2S) wiring from the sub-frame.
Preparatory work for removing the wheel knuckle on the left-hand side
Position fixture 998 5972 JACK 998 5972 Jack under the sub-frame.
Remove the sub-frame screws.
Lower the subframe so that the ball joint for the wheel knuckle detaches.
Note! Install socket 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket on the wheel knuckle ball joint. Do not damage the rubber bellows for the ball joint.
Removing the drive shaft from the wheel knuckle (left-hand side)
Take hold of the drive shaft. Pull it down towards the control arm so that it does not tension.
Pull the brake disc outwards. At the same time, pull on the constant velocity joint towards the transaxle so that the driveshaft loosens.
Allow the drive shaft to lie on the control arm.
Caution! Later models have a rubber seal on the constant velocity joint. Do not damage the seal. It will be needed for installation.
Removing the left drive shaft from the gearbox
Use jimmy bar 999 5736 Wrenches 999 5736 Wrenches.
Note! Do not damage the seal.
Note! Do not under any circumstances pull the drive shaft in such a way that could cause the joints to separate. The joints do not have axial pinions.
Removing the collision protection system over the steering gear (right-hand drive cars)
Note! Applies only to right-hand drive cars.
Lower the sub-frame slightly. Use the mobile jack.
Remove a screw and a screw and nut.
Note! Carefully check that the collision protection system under the steering gear is free and not under stress.
Removing the screw for the rear engine mounting
Remove the screw.
Lowering the sub-frame
Use the mobile jack. Lower the sub-frame approximately 140 mm.
Hang the steering gear from a tie strap.
The steering shaft must not slide out of the rubber boot.
Carefully lower the sub-frame. Let it hang free.
Note! Ensure that the screws for the steering gear on the left side release from the frame.
Removing the rear engine pad
Remove the engine pad on the left side between the bodywork and the three-way catalytic converter (TWC).
Removing the rear engine mounting
Slacken off the 4 screws for the engine mounting.
Twist out and remove the engine mounting.
Removing the oil pipe from the gearbox
Note! Plug the oil pipes so that no dirt gets in.
Remove the nuts from the brackets for the oil pipes.
Remove the screw nipples (counterhold at the connections). Pull out the oil pipes.
Move the oil pipes to one side.
Lower the car.
Lowering the engine and transmission
Lower the engine / transaxle on the left-hand side using the hook.
Lower the engine so that the distance between the upper edge of the mounting bracket and the spark plug cover is approximately 350 mm. See arrow.
Caution! Ensure that the engine mounting is not against the exhaust boot and is not trapped. The exhaust boot must not be damaged.
Raise the car
Removing the heated oxygen sensor (HO2S) connectors from the bracket on the transmission
Disconnect the connectors from the bracket.
Remove the nut on the bracket and the clamp holding the wiring.
Preparations for removal of the transmission
Remove:
- the 2 nuts for the wing liner. Angle out and tie up the wing liner to the lifting beam using a retaining strap
- the ABS line from the spring strut.
Installing the fixture on the mobile jack
Install:
- fixture 999 5463 FIXTURE 999 5463 Fixture on fixture 999 5972 FIXTURE 999 5972 Fixture. Use the fixture and plate together with mobile jacks 998 5972 JACK 998 5972 Jack
- fixture 999 5735 Fixture 999 5735 Fixture on fixture 999 5463 FIXTURE 999 5463 Fixture.
Aligning the fixture on the transmission
Locate fixture 999 5735 Fixture 999 5735 Fixture against the transaxle.
Fold up the side mountings over the edge of the transmission and secure.
Removing the transmission
Remove:
- the 2 screws (on the bracket) at the cover for the differential housing
- the 2 screws positioned furthest in and highest up at the engine/transaxle
- the remaining 4 screws for the engine/transaxle.
Pull the transaxle straight out in relation to the engine.
Note! Lower the transaxle slightly when it is being removed so that it will go past the side member.
Continue pulling the transaxle straight out.
Note! Ensure that the torque converter is also removed.
Flushing the oil cooler and oil hoses
The oil cooler and hoses must always be flushed through when replacing the transmission.
Remove the oil pan. Check for metal particles on the magnet.
Replace the oil cooler and oil pipes if there is:
- Glycol in the transmission fluid
- Metal particles in the transmission fluid
- Burned or dirty oil.