AR27.10-P-0500P Remove/Install Transmission With Torque Converter
AR27.10-P-0500P Remove/install transmission with torque converter
- with TRANSMISSION 722.6 [MODELS 203,209 (except 203.2/05/08/09/28)]
- with TRANSMISSION 722.9 [MODELS 203.052/054/056, 209.356/372/375/376]
Remove/Install
CAUTION: See Notes on self-locking nuts and bolts
DANGER:
- Lethal injuries are possible if vehicle slips off of lifting platform
- Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer
- Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury with caustic burns to eyes and skin from battery electrolyte or from handling damaged lead-acid batteries
- No fire, sparks, naked flames or smoking. Wear acid-resistant gloves, clothing and goggles. Pour battery electrolyte only into suitable and appropriately marked containers.
1 Disconnect ground cable of battery
- Model 209
Caution:
- Do not connect quiescent current retention unit, otherwise this may cause damage to the control modules
2.1 Remove air cleaner
NOTE: Installation: Lightly grease rubber guides to facilitate assembly
2.2 Remove intake air scoop
3 Unscrew oil filler tube from engine
4.1 Detach lower engine compartment paneling
4.2 Remove bottom section of sound-proofing capsule
5 Drain transmission oil at oil pan
CAUTION:
- If the transmission fluid is burnt or contains particles, the oil cooler lines and oil cooler must be flushed out
- Installation: Install new seal in order to avoid oil loss
6 Remove rear exhaust system
7 Support transmission
8 Remove rear engine crossmember (12) with engine mount
NOTE: Do not detach engine mount from rear engine crossmember (12)
9 Disconnect front propeller shaft (17) from transmission
NOTE:
- The flexible coupling remains on the propeller shaft
- Installation: Mount the front propeller shaft on the transmission
10 Loosen fitted sleeves of flexible coupling and push back propeller shaft
11 Press off retainer (63a) using a suitable tool
12 Detach shift rod (63) at floor shift
13 Disconnect plug connector
14 Unscrew bolt holding torque converter to driven plate (95)
NOTE: For this step remove cap.
15 Unscrew lead pipe (21) from oil pan
16.1 Unscrew oil line to oil cooler (left and right) (engines 111, 112) (49) from transmission
16.2 Detach oil line to oil cooler (engines 611, 612) (50)
17 Slacken bolt (50a)
18 Unscrew screw (2)
19 Turn lead pipe (21) down out of the way
20 Remove automatic transmission downwards at an angle using lifting equipment
NOTE: Secure torque converter against falling to avoid damage
21 Remove torque converter
NOTE: Installation: Lightly grease crankshaft journals on torque converter
22 Install in the reverse order
23 Perform basic programming
24 Read out fault memory with STAR DIAGNOSIS and erase if necessary
- Stored faults which may be caused by disconnecting cables or by simulation during removal and installation or test operations, must be processed and erased in the fault memories after completing the work
DANGER:
- Risk of accident. Accidents may result if the vehicle starts off unintentionally with the engine running. Risk of injury as working around the engine during start-up or while running may result in confusions and burns.
- Secure vehicle to prevent it from moving. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.
25 Inspect ATF level in automatic transmission, add ATF if necessary