Install Transaxle

1. Lubricate the primary shaft splines, refer to Specifications, Fluid Types.
2. If the slave cylinder is new or without brake fluid it must be bled, refer to Clutch M/T.





3. Fit the protective collar 83 95 162, in the right shaft seal in the gearbox to protect the seal when the gearbox is being fitted.

IMPORTANT: Always replace the drive shaft seals. Lubricate with gearbox oil.

4. Raise the car.
5. Make sure that the locating studs are in place. Lubricate with thin anti-corrosion oil.





6. Connect the lifting tool MKM 886, 87 92 608. Adjust the lifting tool so its center is aligned with the center of the gearbox and mounting face.
7. Fit the gearbox with lifting tool onto a pillar jack.

IMPORTANT: Push in the gearbox until approx. 20 mm remain and remove tool 83 95 162.

8. Push in the rest of the gearbox. Turn the engine shaft, if needed, so that the gearbox can be fitted.





9. B235R: Position the protective cover plate behind the flywheel. Fit the bolts between the gearbox and engine oil sump as well as the screws to the protective cover.
Tightening torques: Gearbox - oil sump: 40 Nm (30 ft. lbs.)





10. Tighten the lower screws between the engine and gearbox.
Tightening torque 70 Nm (50 ft. lbs.)
11. Remove the lifting tool from the gearbox and remove the jack. Replace and tighten the gearbox bolts,
Tightening torque: 24 Nm (118 ft. lbs.)





12. Fit the ground cables to the mounting and the gearbox.
13. Fit tool 83 95 162 in the left shaft seal.
14. Make sure that the driver is clean and fit it into the tool.

IMPORTANT: Fit the driver in the gearbox until about 20 mm remains and withdraw the tool before the shaft's sealing surface reaches the shaft seal.

15. Push in the rest of the shaft until the circlip snaps into place.
16. Lower the car to the floor.





17. Fit the gearbox mounting.
Tightening torque: 40 Nm (30 ft. lbs.)
18. Connect the clutch delivery line and fit the clips, check that the pipe mounting on the body is firmly attached.
19. Lift the unit.

NOTE: Do not lift higher than necessary, it will only make the fitting of the subframe more difficult.





20. Tighten the left engine pad to the body and gearbox, first fit all the bolts and nuts, then tighten the guide screw first of all to ensure that the correct position is obtained.
Tightening torques:
Engine pad - gearbox: 85 Nm (62 ft. lbs.)
Engine pad - body: 60 Nm (45 ft. lbs.)
21. Fill the gearbox to the correct level. Use the assembly tool 87 92 590. Assembly to Level plug, drain plug and filler plug are to be tightened
Tightening torque: 50 Nm (37 ft. lbs.)
22. Connect the lead to the reversing-light switch.





23. Check that the journals for the radiator assembly are correctly fixated in the radiator member.
24. Unhook the oil cooler.
25. Raise the car and position the lifting trolley with the subframe under the car.
26. Carefully raise the subframe.

IMPORTANT: Watch out for:
- Hoses to the engine oil cooler.
- The rubber gaiters to the inner driver that can knock against the center mountings on the subframe before the subframe comes against the body.
- Guide in the front ball joints.

27. Tighten the steering servo delivery line mountings (2 pcs.) before the subframe is fully raised.
28. Guide the radiator assembly journals into the subframe.
29. Guide the AC-lines into their brackets on the subframe.
30. Adjust the subframe so that the screw holes are aligned with the body. On the lifting trolley there are 2 journals, front left and rear right, which guide the subframe into the correct position.
31. Fit the screws and the rear support plate that secures the subframe.
32. Roll the lifting trolley out the way.





33. Tighten the screws for the subframe.
Tightening torque: 100 Nm + 45° (74 ft. lbs. + 45°)
34. Tighten the screws for the support plate.
Tightening torque: 60 Nm (44 ft. lbs.)
35. Fit the two bolts securing the torque rod to the subframe and tighten them.
Tightening torque: 30 Nm (22 ft. lbs.)
36. Remove the strap that is securing the radiator assembly.
37. Fit the engine oil cooler.
38. Tighten the 2 rear attaching clamps for the steering servo delivery line in connection with the subframe, tighten the nut that secures the oil cooler coil.
39. Tighten down the air filter housing.
40. Tighten down the steering gear.
Tightening torque: 90 (66 ft. lbs.)





41. Tighten the outer ball joints to the steering swivel member.
Tightening torque: 85 Nm (63 ft. lbs.)

WARNING: Check that the journal on the ball joint protrudes above the steering swivel member attachment.

42. Fit the anti-roll bar stay. Take the strain with a thin open ended 17 mm spanner.
Tightening torque: 85 Nm (64 ft. lbs.)

NOTE: To avoid the gaiter being pressed in, a thin spanner should be used for support.





43. Fit the cover plate between the engine and gearbox (not B235R).
44. Fit the rear engine pad, with the screws in place, on the subframe and insert the two front screws.
45. Fit the rear engine mounting, the linkage to the selector mechanism will follow.
Tightening torque: 70 Nm (50 ft. lbs.)
46. Fit the stay between the engine mounting and engine.
Tightening torque: 22 Nm (16 ft. lbs.)
47. Fit the front exhaust pipe, by:
Tightening the flange to the turbo.
Tightening torque: 25 Nm (18.5 ft. lbs.)
Fit and tighten the stay to the engine.
Tightening torque: 22 Nm (16 ft. lbs.)
Fit the clip for the rubber mounting.
Refer also to Information found under Exhaust System and Catalytic Converter.
48. Fit shields and the belt circuit splash guard.
49. Lower the car to the floor.
50. Remove the lifting beam, remove the locating studs and tighten the upper screws between the engine and gearbox.
Tightening torque: 70 Nm (50 ft. lbs.)





51. Shake the powertrain to avoid tension in the engine pads. Tighten the bolts to the rear engine pad from the engine bay side, start with the rear bolts.
Tightening torque: 24 Nm (18 ft. lbs.)
52. Tighten the nut to the rear engine pad.
Tightening torque: 45 Nm (33 ft. lbs.)
53. Raise the car.
54. Slacken the bolt to the front torque arm to the gearbox and center the rubber pad in the arm and tighten.
Tightening torque: 47 Nm (34 ft. lbs.)
55. Lower the car to the floor.
56. Remove the brake clamp from the clutch pedal. Connect a hose to the bleed nipple, loosen it and allow some brake fluid to run out. Tighten the nipple and try the clutch, if it does not work bleed as required, refer to Clutch M/T.
Check that there are no system leaks.
57. Fit the selector linkage to the gearbox and tighten.
Tightening torque: 24 Nm (17.5 ft. lbs.)





58. Remove the locking pin 87 92 335 from the gear lever housing and connect the gear linkage to the selector rod.
59. Select 4th gear and secure with a locking pin 87 92 632. Tighten the clamp on the gear linkage.
Tightening torque: 22 Nm (16 ft. lbs.)
60. Remove the locking pins, check the gear positions and that the ignition key can be removed. Fit the plastic plug in the gearbox. Fit the gaiter.
61. Connect the oxygen sensor/s.





62. Fit the battery tray.
63. Fit and connect the battery, also fit the plastic cover.
64. Fit the front wheels, the wheels must hang freely.
Tightening torque: 11 Nm (80 ft. lbs.)
65. Fit the cover over the throttle body.





66. Fit the grille
67. Test drive the car. Check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed.
68. Set the correct time and radio code.