Installing the Gearbox Side Cover
Installing the gearbox side cover
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.
Note! Carefully clean the gearbox and side cover mating surfaces before installing the gasket. Paper must not be used for cleaning. Paper fragments can cause running problems. Check the marking on the side cover gasket. The gasket can be reused once.
Preparations
Note! The gasket may only be re-used once. Check whether there is a 2 at the top of the right-hand corner of the gasket. The gasket must be replaced if there is a 2 on it. If there is no digit, stamp a 2. This indicates that the gasket has now been reused and must be replaced the next time the side cover is removed. Make this mark to assist other mechanics.
Note! Apply a little petroleum jelly to the new rubber gasket which seals around the drive shaft outlet. This is so that it stays in place in the groove in the side cover on installation.
Installing cover
Note! The side cover has two different holes. The rear smaller hole and the front rectangular hole. These two holes are to guide the cover gasket during installation. Begin installing the cover by installing the two screws.
Apply a little petroleum jelly to the gearbox mating surface.
Install:
- the side cover gasket
- the side cover
- the screws. First tighten the screws crosswise to 10 Nm. Then tighten the screws crosswise to 25 Nm
- the lower three Torx screws. Tighten to 25 Nm
- the bracket for the studs and the screw loosely on the bracket
- the clamp for the stud and the screw. Tighten to 25 Nm. Tighten the screw for the bracket. Tighten to 25 Nm
Clamp the wiring up on the bracket. Use new tie straps.
Lifting the engine and gearbox to the horizontal position
Installing the oil pipes
Install:
- the oil pipe with the nipple to the terminal on the gearbox. Counterhold on the connection. Tighten to 30 Nm
- the nut and washer for the oil pipe brackets. Tighten to 25 Nm.
Installing the rear engine mounting
Install the rear engine mounting.
Installing the screw for the rear engine pad through the steering gear
Install the screw for the rear engine pad.
Installing the collision protection system over the steering gear
Applies only to right-hand drive cars
Install the collision protection on the steering gear.
Installing the sub-frame on the bodywork
Install the sub-frame on the bodywork according to Transmission, installing Gearbox, Installing.
Installing the left drive shaft on the gearbox, stub axle and control arm
Install the left drive shaft in the gearbox according to Transmission, installing Gearbox, Installing.
Installing and tightening the sub-frame screws
Install and tighten the sub-frame screws according to Transmission, installing Gearbox, Installing.
Installing the screws for the bracket for the heated oxygen sensor (HO2S) cable
Install the screws for the bracket for the heated oxygen sensor (HO2S) cable.
Installing the front cross member
Install:
- the screws for the exhaust pipe mounting. Tighten to 10 Nm
- the brake pipe in its holders
- the screws for the cross member. Tighten to 25 Nm.
Secure the heat deflector using rivets (early version).
Installing new lock nuts on the steering gear
Install new lock nuts on the steering gear.
Installing the screw for the front engine pad and the torque rod mounting in the gearbox
Install the screw for the front engine pad and the torque rod mounting in the gearbox.
Installing the screws for the cable conduit and the ground lead bracket
Tighten to 10 Nm.
Note! Cars with parking heaters: Install the heater in the bracket. Tighten the nuts. Tighten to 25 Nm.
Reinstall the fuel line in the clips on the sub-frame.
Installing and tightening front end components (both sides)
Install and tighten the front end components according to Transmission, installing Gearbox, Installing.
Tightening the ball joint pinion
Tighten the ball joint pinion according to Transmission, installing Gearbox, Installing.
Lower the car.
Remove the lifting beam and the lifting hook from the engine and the car
Remove the lifting fixture from the motor. Reinstall the screws. Tighten to 50 Nm.
Reinstall the spark plug cover. Tighten the screws. Tighten to 10 Nm.
Install the ground strip. Tighten to 10 Nm.
Applies only to turbocharged cars
Lift up the delivery lines. Install the spark plug cover.
Tighten the screws.
Installing all the charge air pipes
Applies only to turbocharged cars
Connect all the charge air pipes to each other.
Tighten the hose clamps.
Install the screws for the charge air pipe in the intake manifold. Tighten to 10 Nm.
Install the hose on the heater pipe in the bulkhead.
Press the radiator hose quick-release connector into place on the heater pipe.
Check: Pull the hose.
Installing the connector
Install:
- the screw for the clamp for the positive cable
- the cable in the clips on the side member
- the connector for the gearbox. Press it into place properly.
Caution! It is important that the connector is pushed into place properly. If it is not correctly connected the gear shift function may stop.
Installing the upper torque rod
Install:
- the torque rod. Tighten the mounting screws. Tighten to 50 Nm
- the screw and a new nut for the engine mounting. Tighten to 80 Nm
- the plastic guard over the spring strut (if applicable). Tighten the screws.
Installing the air cleaner (ACL) housing
Install the air cleaner (ACL) housing. See Brake pipe master cylinder / ABS unit, replacing Brake Pipe Master Cylinder / ABS Unit, Replacing.
Filling the gearbox with fluid
Note! Oil grade: Only automatic gearbox fluid (ATF). Dexron III (the fluid must have a G license)*. *This is usually given as "Dexron III (G-xxxxx)" where xxxxx is a 5 digit serial number. "Dexron III-G" (without a number) may also occur. Dexron II D and II E must not be used.
Note! Filling with oil: Start by filling with 5.5 liters of oil.
Refilling gearbox oil There are three different methods. Method 1
Note! Filling with oil: Start by filling with 5.5 liters of oil.
Fill the gearbox with oil. Use a funnel with a plastic hose. Fill through the dipstick pipe.
Clear up any oil spillage under the dip stick pipe.
Refilling gearbox oil Methods 2 and 3
Note! Filling with oil: Start by filling with 5.5 liters of oil.
Method 2
Use a converted five liter plastic can (see the illustration).
This method avoids oil spillage. It also provides a more regular flow when filling.
To check the oil level, see Oil level, checking Checking Oil Level.
Method 3
Push in the oil from the hydraulic pump.
Note! After changing transmission oil, the transmission's adaption as well as the counter for "Transmission oil, change" shall be reset. Use VIDA Vehicle communication to reset adaption and counter.
Check the coolant level in the expansion tank
Top up with water and coolant as necessary (when the engine is at operating temperature).
Raise the car.
Check that there is no oil leakage at:
- the connections for the oil pipes on the gearbox
- the side cover
- the side cover around the drive shaft.
Installing the splash guards and the wing liner
Install:
- The ABS-cable on the mounting
- the splash guard under the engine
- the front splash guard
- the nut for the left wing liner
- the wheels. See Installing wheels Service and Repair.
Lower the car
Checking the steering gear bearing in the boot at the bulkhead
Check the steering gear bearing in the boot at the bulkhead.
Installing the battery lead
See Battery, disconnecting Battery Disconnecting. It is essential that the instructions are followed.
Test driving the car
Note! Test drive the car in the same way as before the repair. See Transmission checking/fault-tracing Transmission Checking/Fault-Tracing.
In the event of faults other than vibrations (judder)
For information about test driving the car, see Test Drive Form, description Test Drive Schedule, Description.
Note! After changing transmission oil, the transmission's adaption as well as the counter for "Transmission oil, change" shall be reset. Use VIDA Vehicle communication to reset adaption and counter.