Transmission, Installation
Transmission, installing
Special tools:
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
999 5045 COMPRESSION HOOK 999 5045 Compression Hook
999 5460 Lifting hook 999 5460 Lifting Hook
999 5563 SUPPORT 999 5563 Support
Installing the gearbox
Use the mobile jack and gearbox fixture to adjust the height and angle. Locate the gearbox on the engine.
Install the 6 screws. Tighten alternately to a light contact. Then tighten the screws alternately to 50 Nm .
Note! When tightening the screws, check carefully that the guide bushings locate correctly in their guide holes. Check that the torque converter cover is in contact with the engine before tightening.
Remove the fixture and the mobile jack from the gearbox.
Installing the torque converter screws
Note! Use new screws, Torx TX50.
Align the torque converter with the carrier plate by turning the engine with the crankshaft pulley nut and turning the torque converter (accessible through the hole in the cover).
Install all 6 screws loosely. Tighten the screws until the heads are in contact with the carrier plate. Then tighten to 35 Nm . Socket Torx TX 50.
Note! Remove the socket wrench from the crankshaft.
Lifting the engine and gearbox
Screw up lifting hook 999 5460 Lifting hook 999 5460 Lifting Hook
Ensure that the dip stick pipe is free of the fan and that that no hoses or cables are crimped.
Installing the rear engine mounting on the gearbox
Install the mounting on the gearbox (3 screws). Tighten to 50 Nm .
Installing the screw for the rear engine mounting
Install the screw in the engine pad. Tighten the screw to 50 Nm .
Remove the load relieving hook 999 5045 COMPRESSION HOOK 999 5045 Compression Hook or the tie strap.
Install:
- the heated oxygen sensor (HO2S) cable on the cover with clamps
- the ground lead to the gearbox.
Right-hand drive cars only
Remove the tape from the drive shaft and let the shaft rest on the oil pipe.
Raise the sub-frame so that it is approximately 100 mm from the body.
Locate the steering gear on right side and the crash guard in the sub-frame. Install the screws on the anti-roll bar left bearing cap. Tighten both bearing caps. Tighten to 50 Nm .
Installing the sub-frame
Note! Use new screws (4 x M14). Lubricate the screw threads. Ensure that the steering gear screws are aligned in the frame!
Begin on the left-hand side. Raise the sub-frame with the mobile jack.
Install the screws for the frame and the support plate. First tighten the frame screws to 105 Nm + 120° and then the screws for the frame bracket to 50 Nm . Use bevel protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.
Installing the oil pipe on the gearbox
Use a new O-ring. Tighten to 10 Nm .
Installing the nuts and the screws on the steering gear and the front engine pad
Install:
- the 5 screws for the steering gear nuts. Use new nuts. Tighten to 50 Nm.
- the nut for the collision protection system / sub-frame (A). (Right-hand drive cars only) . Tighten to 50 Nm
- the screw for the front engine mounting - sub-frame.
Tighten the screws on the front and rear engine pads. Tighten to 50 Nm .
Installing the right drive shaft
Note! Ensure that the seal ring in the gearbox and the boot on the drive shaft are not damaged.
Install the bearing cap. Tighten to 25 Nm .
Installing the torque rod mounting in the gearbox
Note! Use new screws.
Tighten to 50 Nm .
Install the screws in the brackets for the oil pipes. Tighten to 25 Nm .
Installing the collision protection system over the steering gear (right-hand drive cars only)
Tighten the two screws to 80 Nm .
Installing the left drive shaft
Ensure that the ABS sensor pulse wheel on the drive shaft is free of dirt.
Press in the drive shaft firmly so that the snap ring engages in its groove in the differential gear. Check by pulling carefully on the drive shaft constant velocity joint.
Note! Ensure that the seal ring in the gearbox and the boot on the drive shaft are not damaged.
Installing the drive shaft on the hub
Use holder 999 5563 SUPPORT 999 5563 Support to hold the control arm down.
Bend out the spring strut. Align the drive shaft in the hub.
Install the drive shaft screw by hand. Use a new screw.
Remove the holder.
Note! Take care not to damage the drive shaft boot.
Installing the ball joint on the stub axle
Clean off any rust from the ball joint and stub axle.
Lubricate the ball joint pinion and the stub axle.
Install the ball joint in the stub axle.
Note! Press the ball joint upwards so that the conical top is visible above the screwed joint on the stub axle.
Install:
- the screw for the ball-joint. Use a new nut. Tighten to 50 Nm
- the anti-roll bar link. Use a new nut. Tighten to 50 Nm
- the track rod with a new nut. Tighten to 70 Nm .
Tightening the left drive shaft screw
See.
Installing front suspension components
Install:
- the bracket for the brake line / ABS cable (both sides)
- the ABS sensor in the stub axle. Clean the sensor with a soft brush.
Note! Ensure that the sensor seat is absolutely clean.
Tighten the sensor to 10 Nm .
Install the plastic nut (both sides).
Rivet the fender liner into place.
Installing components on the underside of the car
Install:
- the cable conduit on the sub-frame
- the carbon filter container. Clamp the hoses to the sub-frame with tie straps. Hook the hoses into place in the sub-frame
- the bracket and the screw for the ground lead.
Installing the front cover and the wheels
Install:
- the front cover. Press it into position at the front. Press it forward and upwards at the rear so that cover guide is seated in its slot. Install the screws
- the wheels.
Lower the car
Removing the lifting hook and lifting beam
Remove:
- the lifting hook and the lifting beam
- the lifting fork from the engine.
Tighten the nut for the rear engine pad. Tighten to 50 Nm .
Installing the screws between the gearbox / engine and the gearbox / starter motor
Install:
- the 3 screws for the gearbox / engine. Tighten to 50 Nm
- the 2 screws for the gearbox - starter motor. Tighten to 40 Nm
- the cable duct on the gearbox.
Installing the gearbox cable, mounting and oil pipe on the gearbox
Install:
- the gearbox cable on the lever and the screws for the bracket on the gearbox. Tighten to 25 Nm
- the large connector
- the 2 nuts for the cable conduit on the gearbox
- the connector at the cable conduit furthest in at the gearbox
- the oil pipe on the gearbox. Tighten to 25 Nm .
Installing the screw for the torque control arm / torque rod at the engine
Tighten to 35 Nm + 90° .
Install the ground strip on the firewall. Tighten to 10 Nm .
Installing the connectors and vacuum hose
Install:
- the connector under the panel
- the connector on the fan shroud
- the vacuum hose on the intake manifold.
Installing engine compartment components
See Sealing ring, gear shift linkage rod, replacing Sealing Ring, Gear Shift Linkage Rod, Replacing
Finishing
Checking gearbox fluid level
See Checking the oil level Checking Oil Level.
Note! If the gearbox is replaced with a new or exchange gearbox, it is supplied filled with oil plus a certain amount of "excess". This is to compensate for loss from the oil cooler. The oil level must always be checked however.
Warning! The lower engine coolant hose positioned by the dip stick is extremely hot. Use protective gloves when moving the hose to the side.
Test drive the car
Use the test driving schedule, see Test drive schedule, description Test Drive Form, Description.
Note! After replacing the transmission, the transmission adaptation and the "Transmission oil change" counters must be reset. See Resetting the adaptation, AW55-50/51SN Resetting Adaptation.