Removal and Installation

Automatic Transmission

Removal
1. Select N gear position.
2. Disconnect the battery ground lead.
3. Remove the engine covers. Refer to Engine.
4. Remove the air intake tube, MAFM and air cleaner cover assembly. Refer to Powertrain Management.





5. Disconnect the transmission link lead connector.
Release the connector from its mounting bracket.
Disconnect the multiplug.





6. Remove the EMS harness mounting bracket.
Release the bolt, bracket to cylinder head.





7. Fit engine lifting bracket 303 - 536 at the rear RH.





8. Remove the center trim panel from the engine compartment.
Remove the left hand side enclosure panel.
Remove the center trim panel.





9. Move the coolant header tank for access.
Disconnect the bleed pipe, header tank to radiator.
Remove the header tank fixings.





10. Fit engine lifting bracket 303 - 536 at the rear LH.





11. Support the engine using 303 - 021.
Adjust and locate the side support brackets to fit into the LH and RH body channels and tighten the beam fixings.
Engage the support hooks into the engine rear lifting brackets.
Tighten the support hook adjusters to take the weight of the engine.
12. Raise the vehicle for access.
13. Remove the LH downpipe catalytic converter. Refer to Powertrain Management.
14. Remove the front muffler. Refer to Exhaust Systems.
15. Remove the RH downpipe catalytic converter. Refer to Powertrain Management.
16. Drain the transmission fluid.





17. Locate an Epco V-100, or similar lift, under the transmission unit.
Adjust the angle of the lift to suit the transmission.
Secure the side clamps.
Pass the safety chain over the transmission unit and tighten the clamp to secure the assembly.





18. Remove the rear engine mounting bracket.
Remove the center bolt from the engine/transmission mounting.
Remove the four bolts which secure the mounting bracket to the body.





19. Detach the driveshaft (prop-shaft) from the transmission drive flange.
If the transmission is to be refitted, mark the position of the coupling relative to the drive flange.

CAUTION: Under no circumstances remove the driveshaft to flexible coupling fixings.

Remove the transmission drive flange to flexible coupling fixings.





20. Lower the transmission unit.





21. Detach the gear selector cable from the transmission unit.
Remove the selector cable ball pin to selector lever nut.
Lower the transmission lift for access.
Remove the selector cable to transmission casing bolts.





22. Release the transmission harness multiplug bracket.
Remove the two bolts which secure the bracket to the transmission case, noting that one bolt also retains the dipstick tube.





23. Disconnect the fluid cooler upper pipe.
Remove the bolt which secures the pipe to the cylinder block and remove the bracket.
Remove the 'banjo' bolt.
Discard the Dowty seals.
Fit blanking plugs to the pipe and transmission.





24. Disconnect the fluid cooler lower pipe.
Remove the 'banjo' bolt.
Discard the Dowty seals.
Fit blanking plugs to the pipe and transmission.





25. Remove the three bolts which secure the torque converter to the drive plate.
Remove the access cover.
Rotate the crankshaft for access to each bolt and hold to prevent movement. Remove each bolt.





26. Remove the LH and RH catalyst mounting brackets from the transmission case.
Remove the two bolts from each side.
27. On the RH side, clear the cooler pipe for access.





28. NOTE: Viewed from the rear of the vehicle.

Remove the two upper bolts, as indicated, transmission to engine.





29. NOTE: Viewed from the rear of the vehicle.

Remove the two bolts which secure the starter motor power cable clip.





30. NOTE: Viewed from the rear of the vehicle.

Remove the ground lead bolt.
31. On the LH side.





32. NOTE: Viewed from the rear of the vehicle.

Remove the bolt which secures the cooler upper pipe clip to the transmission case.





33. NOTE: Viewed from the rear of the vehicle.

Remove the six remaining bolts from the transmission case to cylinder block.





34. NOTE: Do not allow the converter to detach from the transmission.

Remove the transmission / converter assembly from the vehicle.
Lower the lift and remove the transmission, ensuring that the torque converter spigot disengages cleanly.





35. Remove the side clamps and chain for access.





36. Remove the front muffler mounting bracket.
Remove the two bolts which secure the bracket to the transmission case.





37. Remove the transmission dipstick tube.
Remove the fixing which secures the tube to the case.
Discard the filler tube 'O' ring.
Fit a blanking plug to the transmission casing orifice.





38. Remove the harness link lead.
If required, slacken the harness heatshield spring clamp bolt.
Remove the heatshield lower bolt.
Release the harness multi-lock lever, disconnect and remove the harness.
39. If appropriate, fit retaining straps to the converter / transmission assembly.

Installation

1. CAUTION: A new transmission requires a NEW torque converter.

Installation is the reverse of the removal procedure, noting the following:
2. Clean all mating faces and relevant parts.





3. Apply lubricant, MOLYCOTE or equivalent to the torque converter spigot.





4. Fit the screw (lower) securing the harness link lead heatshield. Tighten to the specified torque figure.





5. Fit the dipstick lower tube.
Remove the blanking plug and fit a new O-ring seal Tighten the bolt to the specified torque figure.





6. Fit the mounting bracket for the front muffler. Tighten the two bolts to the specified torque figure.





7. Secure the transmission to the engine.
Loosely assemble - Cooler pipe clip bolt.
Loosely assemble - Ground lead bolt.
Loosely assemble - Starter cable clips, two bolts.
Loosely assemble - Catalyst bracket bolts, two each side.
Loosely assemble - Remaining eight bolts.
Refer to the illustration - tighten in sequence 1,2,3,4 then in any order.





8. Secure the torque converter to the engine.
Fit, but do not tighten, the three bolts which secure the torque converter to the drive plate.
Prevent crankshaft rotation and tighten ALL converter bolts to the specified torque figure.
Fit the blanking plug to the cylinder block access aperture.





9. Secure the oil cooler pipes.
Fit new Dowty washers to each union. Connect the upper and lower cooler pipes. Tighten to the specified torque figure.





10. Refit the harness connector support bracket and tighten the two bolts to the specified torque figure, noting that one fixing also retains the dipstick upper tube.





11. Connect the selector cable. Tighten the bolts and one nut to the specified torque figure.





12. Connect the driveshaft (prop-shaft) aligning the marks made when it was removed. Tighten the bolts to the specified torque figure.





13. Fit the rear crossmember. Tighten the bolts to the specified torque figure.





14. Refit the coolant header tank. Tighten to the specified torque figure.





15. Fit the harness and clip (transmission link harness) to the rear of the cylinder head. Tighten to the specified torque figure.
16. Refer to fluid fill procedure. Fluid - A/T