Transmission Installation

Complete Automatic Transmission

To Fit

When fitting a new transmission, transfer the holder for the torque converter from the new transmission to the old one.





1. Turn the torque converter so that the bolt holes line up with the holes in the drive plate.
Fit 87 92 574 Holder to keep the torque converter in place while fitting.
2. Make sure the two guide sleeves are on the engine and apply anti-corrosion agent to the sleeves.
Fit new drive shaft seals, lubricate them before fitting. Use 87 92 657 Fitting drift, drive shaft seals.
3. Lift up the gearbox using an engine hoist and 87 92 442 Lifting cable.





4. Fit 87 92 608 Holder for pillar jack on a pillar jack.





5. Secure the tool to the transmission as described for removal.

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





6. Fit 83 95 162 Protective collar, drive shafts in the right-hand shaft seal in the transmission to protect the seal when the transmission is being fitted.
Lubricate the seal.
7. Place the transmission in position.

IMPORTANT: Push the transmission into place until approx. 20 mm remains and then remove tool 83 95 162.





8. Tighten the bottom bolts between the engine and the transmission.
Tightening torque 75 Nm (55 ft. lbs.)
9. Remove the lifting beam from the transmission and move the jack out of the way.
Refit the bolts in the gearbox.
Tightening torque 24 Nm (18 ft. lbs.)
10. Lower the car and fit the engine pad mounting on the gearbox.
Tightening torque 60 Nm + 60° (44 ft. lbs. + 60°)
Raise the powertrain.
Do not lift higher than necessary as this could make fitting to the subframe more difficult.
Fit the bolts securing the engine pad to the body.

NOTE: One of the rear bolts is shorter in order not to screw into the bottom of the hole. Ensure that the bolt holes are as close as possible to the center of the engine pad holes without tensioning the engine pad.

Tightening torque, bolt with loose washer 63 Nm (46 ft. lbs.)
Tightening torque, bolt with captive washer 40 Nm + 30° (30 ft. lbs. + 30°)
Tightening torque, nut 84 Nm (62 ft. lbs.)
11. Lower the engine assembly so that it is almost hanging free in the lifting beam.





12. Fit 83 95 162 Protective collar, drive shafts into the sealing ring. Lubricate the sealing ring.
13. Make sure that the drive shaft is clean and then align it with the tool.

IMPORTANT: Insert all but 20 mm of the drive shaft in the transmission and then withdraw the tool before the shaft's sealing surface reaches the shaft seal.

14. Push in the rest of the shaft until the circlip clicks in.
15. Raise the car.





16. Remove 87 92 574 Holder that is keeping the torque converter in place and press it against the drive plate.
Fit the plug.
17. Apply 74 96 268 Thread locking adhesive to the bolts securing the torque converter to the drive plate.

NOTE: Use the original bolts and their washers. If excessively long bolts are fitted, the torque converter will be damaged.

18. Fit the 3 bolts without tightening them.
19. Rotate the engine using the drive belt pulley and tighten the bolts when they are all in place.
Tightening torque 30 Nm (22 ft. lbs.)
20. Fit the splash plate.





21. Fit the oil cooler hoses. The hoses should be horizontal so that they do not chafe against the subframe.
Use new seals greased with petroleum jelly.
Tightening torque 27 Nm (20 ft. lbs.)
22. Fit the bracket for the torque arm on the transmission.
23. Connect the ground cable to the bracket and to the transmission.
24. Place the subframe on the lifting trolley and raise it slightly.





25. Fit the power steering delivery pipe's clamps.
26. Lift up the subframe, while guiding it into place with the help of the pins on the holder.
At the same time guide in:
- The radiator core's studs
- The AC pipes
- Outer ball joints
27. Fit the bolts to the subframe and fit the rear support plates
Adjust the subframe so that the guide pins on the holder are aligned with the holes in the body before tightening the bolts.
Tightening torque, subframe bolts 100 Nm + 45° (74 ft. lbs. + 45°)
Tightening torque, support plate bolts 60 Nm (44 ft. lbs.)

Note:
^ The center bolts on the subframe must not be mixed up with the other bolts. The center bolts have smaller washers and 20 mm heads.
^ Make sure that the transmission's oil cooler hoses do not rest against the subframe.

28. Remove the lifting trolley.





29. Fit the bolts securing the outer ball joint to the steering knuckle housing.
Tightening torque 50 Nm (37 ft. lbs.)

IMPORTANT: Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.

30. Tighten the anti-roll bar link.
If the wrench use to hold it is too wide to fit between the boot and the suspension strut, it must be ground narrower. Alternatively, hold the hexagonal pin with a socket.
Tightening torque 84 Nm (62 ft. lbs.)
Tightening torque, nut with steel lock: 95 Nm (66 ft. lbs.)





31. Fit the steering gear bolts and tighten them.
Tightening torque 90 Nm (66 ft. lbs.)
32. Remove the strap round the radiator core.
33. Fit the engine oil cooler.
Tighten the air cleaner casing.
34. Tighten the torque arm on the subframe
Tightening torque 90 Nm + 90° (66 ft. lbs. + 90°)





35. Loosely fit the rear engine pad by putting the bolts in place.
36. Lower the vehicle and tighten the engine pad bolts from above.
Tightening torque 24 Nm (18 ft. lbs.)
37. Lift the vehicle and fit the engine bracket to the transmission.
Tightening torque 60 Nm + 60° (44 ft. lbs. + 60°)





38. Fit the front exhaust system.
Tightening torque: 25 Nm (18.4 ft. lbs.)
39. Run the wiring for the oxygen sensor into the engine bay.
40. Fit the covers.
41. Lower the car to the floor.
42. Remove the lifting beam.





43. Connect the oxygen sensors
44. Shake the unit to ensure there is no tension in the engine pads.
Tighten the rear engine pad nuts.
Tightening torque 45 Nm (33 ft. lbs.)





45. Fit the bolts securing the transmission to the engine and tighten them.
Tightening torque 70 Nm (52 ft. lbs.)
46. Clean and fit the dipstick tube.
47. Fit the transmission's breather hose.
48. Fit the shifting cable to the bracket on the transmission.
Fit the clamp.
49. Fit the shifting cable to the selector lever in position P.
50. Check and if necessary adjust the position of the selector lever.





51. Raise the car. Slacken the bolt securing the front torque arm and center the rubber pad in the arm. Tighten the bolt.
Tightening torque, torque arm to subframe 90 Nm + 90° (66 ft. lbs. + 90°)
Tightening torque, torque arm to bracket 70 Nm + 90° (52 ft. lbs. + 90°)





52. Lower the car.
Plug in the connectors to the transmission.





53. Fit the main fuse box.
54. Fit the battery tray and the Maxi fuse holder.





55. Fit the battery and battery cover.
56. Fit the upper engine cover.
57. Fit the front wheels.
58. Fill to the correct level with transmission fluid as per Weight, fluid capacity and grade of fluid.
59. If the transmission has been changed and the oil is contaminated flushing equipment 87 91 824 must be connected before starting the car.
60. Test drive the car with varying engine loads and rpm and read any trouble codes that are generated.
Also check the position of the steering wheel when driving straight ahead on a level road.
Adjust if needed.
Perform Adaptation, resetting.
61. Set the right time on the clock.