Removal
REMOVAL1. Select Neutral gear position.
2. Disconnect the battery.
NOTE: The door opening drop-glass feature will not operate after disconnection of the battery.
3. Remove the air intake components.
4. Install engine lifting bracket JD - 222 or equivalent, at the rear right-hand position.
- Tighten the lifting bracket to engine securing bolt.
5. Reposition the coolant header tank for access, as follows:
a. Remove the securing bolt.
b. Detach the header tank dowels from the mounting grommets.
6. Install engine lifting bracket JD - 222 or equivalent, at the rear left-hand position.
- Tighten the lifting bracket to engine securing bolt.
7. Fit engine support MS - 53C or equivalent, as follows:
a. Correctly position the channel stands and tighten the securing nuts and bolts.
b. Engage the support hooks in the lifting brackets.
c. Tighten the support hook nuts to take the weight of the engine.
8. Raise the vehicle on a four-post ramp.
9. Remove the left and right hand down pipe catalytic converters.
10. Remove the front muffler.
11. Drain the transmission fluid.
12. Remove the rear engine mounting bracket, as follows:
1. Remove the rear engine mounting to bracket securing bolt.
2. Using a ramp jacking channel, position a jack under the rear engine mounting point.
3. With a suitable piece of wood on the jack head, operate the jack to support the bracket.
4. Remove the mounting bracket to body securing bolts.
13. Lower the jack.
WARNING: ENSURE THAT THE RAMP END-STOPS ARE IN POSITION WHEN MOVING THE VEHICLE.
CAUTION: Under no circumstances remove the driveshaft to flexible coupling fixings.
14. Detach the driveshaft from the transmission unit.
- Mark the position of the coupling to drive flange.
1. Remove the transmission drive flange to flexible coupling fixings.
15. Slacken the engine support hook nuts to lower the transmission unit.
16. Detach the gear selector cable from the transmission unit, as follows:
1. Remove the selector cable ball pin to selector lever securing nut.
2. Remove the selector cable to transmission casing securing bolts.
17. Disconnect transmission harness multiplug EM046, as follows:
1. Rotate to release the harness locking lever.
2. Disconnect the harness multiplug.
18. Reposition the rotary switch clear of the transmission unit.
1. Remove the switch securing bolts.
2. Displace the switch harness from the flange clamps.
19. Disconnect the fluid cooler pipes from the transmission unit.
- Release the union nuts.
- Discard the O-rings.
- Fit blanking plugs to the pipes & transmission unit.
20. Release the torque converter from the drive plate.
1. Remove the blanking plug from the cylindar block aperture.
2. Whilst preventing crankshaft rotation, remove the six (6) drive plate to torque converter bolts.
21. Remove the left and right hand downpipe catalyst mounting brackets.
- Remove the bracket to transmission unit securing bolts.
22. Reposition the engine harness multiplug mounting bracket for access.
- Remove the bracket to transmission unit securing bolts.
NOTE: The arrows are shown as viewed from the rear of the vehicle.
23. Remove the (5) upper transmission unit to engine securing bolts.
- One bolt also secures a fluid cooler pipe.
WARNING: ENSURE CORRECT USE OF LIFT INCLUDING SIDE CLAMPS, SECURING PEG & SAFETY CHAIN AS APPROPRIATE
24. Position an Epco V -100 or similar lift under the ramp and take the weight of the transmission unit.
- Pass the safety chain over the transmission unit, engage in the side arm of the lift and tighten the chain adjuster.
25. Remove the transmission unit from the engine.
- Remove the remaining transmission unit to engine securing bolts.
26. Lower the lift and remove the transmission unit.