Transmission Installation

To fit





When fitting a new gearbox, transfer the holder 87 92 277 for the torque converter from the new gearbox to the old one. Also, transfer the front engine mounting and selector [ever cable mounting from the old gearbox to the new one.

1. Turn the torque converter so that the bolt holes line up with the holes in the drive plate.
2. Make sure the two guide sleeves are fitted on the engine. Lubricate the sleeves with a thin layer of anti-corrosion oil.
Fit new drive shaft seals, lubricate the seals.





3. Attach the lifting tool MKM-886, part no. 87 92 608.





Adjust the tool, if its setting has been changed since removal, so that it is centered on the lifting lug on top of the gearbox and tighten it to the gearbox.
4. Fit the gearbox using the lifting too] and a pillar jack.

A Warning: The pillar-type jack may tip over. Exercise care.





5. Fit protective collar 83 95 162 in the right-hand shaft seal on the gearbox to protect the seal when the gearbox is fitted.
6. Place the gearbox in position.

Important Push the gearbox Into place until about 20 mm remains and then remove tool 83 95 162.





7. Tighten the bottom bolts between the engine and the gearbox.
Tightening torque: 75 Nm (55 ft. lbs.)





8. Fit the rear engine mounting on the gearbox.
Tightening torque: 40 Nm (30-ft. lbs.)
9. Lift the powertrain with a jack and tighten the left-hand engine mounting on the body.
Tightening torque: 62 Nm (46 ft. lbs.)
10. Remove the lifting tool from the gearbox and remove the jack.
11. Remove tool 87 92 277 that Is holding the torque converter In position. Fit the plug.
12. Apply Loctite 242 (74 96 268) to the bolts securing the torque converter to the drive plate.

Note: Use the original bolts with washers. If the bolts are too long, the torque converter will be ruined.

13. Fit the 6 bolts without tightening them.





14. Tighten them when they are all fitted in place.
Tightening torque: 60 Nm (44 ft. lbs.)
15. Fit the splash guard.





16. Fit protective collar 83 95 162 in the sealing ring.
17. Make sure that the drive shaft is clean and then align it with the too].

Important: Insert all but 20 mm of the drive shaft in the gearbox and then withdraw the tool before the shaft's sealing surface reaches the shaft sea].

18. Push in the rest of the shaft until the circlip clicks in.
19. After replacement of the gearbox, the cooling circuit should be cleaned if the oil is contaminated. See Cleaning the cooling circuit .





20. Attach the Inlet and outlet hoses for the transmission fluid cooling. Make sure they do not rest on the subframe. Use new seals lubricated with Vaseline.
Tightening torque: 27 Nm (20 ft. lbs.)





21. Carefully raise the subframe. Make sure the washers on the rear mountings are in place and then position the suspension arm end pieces.
22. Adjust the subframe so that the bolt holes are aligned with the body.





23. Tighten the 4 corner bolts on the subframe.
Tightening torque:
front 115 Nm (85 ft. lbs.)
rear 110 Nm (81 ft. lbs.) + 75°
24. Lower the lifting trolley and move it away.
25. Tighten the remaining bolts on the subframe.
Tightening torque: centre 190 Nm (141 ft. lbs.)
26. Tighten the nuts on the rear engine mounting.
Tightening torque: 50 Nm (37 ft. lbs.)
27. Tighten the suspension arm end pieces on both sides and tighten the nuts.
Tightening torque: 75 Nm (55 ft. lbs.)
28. Attach the ground lead to the end of the gearbox.





29. Refit the air shields and the lining In the right wheel housing.





30. Fit the front exhaust pipe and put back the clips for the oxygen sensor cable.
Tightening torque, exhaust flange: 40 Nm (30 ft. lbs.)
Tightening torque, mounting: 25 Nm (19 ft. lbs.)
31. Fit the front wheels.
Tightening torque: 110 Nm (81 ft. lbs.)
Lower the car to the floor.





32. Take away the lifting beam and tighten the top bolts between the engine and the gearbox.
Tightening torque: 75 Nm (55 ft. lbs.)





33. Connect the oxygen sensor and attach the clips.
34. Fit the positive cable mounting on the engine.
35. Plug in the electrical connections for the gearbox (located on a bracket behind the battery).





36. Clean and fit the dipstick pipe.
37. Fit the gearbox breather hose.
38. Fit the shifting cable to the bracket on the gearbox. Fit the clamp.
39. Mount the shifting cable on the selector lever.
40. Fit the cover over the Intake manifold, alternatively the resonator, with hoses and mass air flow sensor.
41. Check and if necessary adjust the position of the selector lever. See Selector lever .





42. Connect the battery negative cable to the grounding point on the gearbox.
43. Fit the battery.
44. Fill with Texaco Texamatic or DEXRON 111 (7045 EU, TL1863 US) mineral based fluid to the correct level.
45. Test drive the car at varying loads and engine speeds, and read any diagnostic trouble codes. Also, check the position of the steering wheel when driving straight ahead on a level road. Adjust if necessary.