Transmission Removal

Complete Automatic Transmission

To Remove:





1. Place drapes over the wings to keep the paintwork clean and protect it from damage.





2. Remove the upper engine cover.
3. Remove the battery cover and the battery.
4. Remove the MAXI fuse board and remove the battery tray.





5. Disconnect the electrical distribution unit and move it aside.





6. Unplug the connectors. The connectors are mounted in a holder.





7. Remove the breather hose from the transmission.
8. Remove the gear selector arm from the gearbox.
The selector lever must be in position L.
9. Remove the clamp and press out the shifting cable, using a suitable screwdriver.
10. Remove the three upper bolts for the gearbox.
Use 87 92 723 Access tool, bolt in joint between automatic transmission and engine to facilitate removing the rearmost bolt.
11. Clean the area round the dipstick tube where it enters the transmission.
12. Remove the dipstick tube and plug the hole.





13. Unplug the oxygen sensor connectors.
14. Remove the nut for the rear engine mounting.
15. Undo the two bolts which hold the rear engine pad, do not remove the bolts.
The third engine pad bolt is inaccessible because of the engine bracket and is removed from underneath when this is removed.





16. Position 83 94 850 Lifting beam and relieve the weight of the engine and transmission.

IMPORTANT: Place suitable protective pads or the like under the feet of the lifting beam to avoid damaging the paintwork.

17. Raise the car.
18. Remove the front wheels.
19. Remove the lower engine cover.





20. Dismantle the front exhaust system. Be careful with the oxygen sensors.





21. Remove the rear engine bracket and the engine pad.





22. Remove the screws securing the steering gear.
23. Remove the two rear clamps securing the power steering delivery pipe to the subframe.
Remove the AC pipes from the plastic clips on the subframe at the same time.
24. Remove the air cleaner casing from the subframe.
25. Detach the engine oil cooler from the charge air cooler.
26. Fit a 83 95 212 Strap around the radiator core and the radiator crossmember.





27. Remove the bolts securing the outer ball joints to the steering knuckle housing on both sides.
28. Detach the upper anti-roll bar ball joints.
Use a 17 mm spanner to prevent the boot from twisting.
If the spanner 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.





29. Remove the torque arm from the subframe and remove the rear support plates.
30. Assemble the holder, using tools 83 95 170 Spacer, 83 95 196 Holder, front, 83 95 188 Basic fixture and 83 95 311 Trolley lift
31. Place the lifting trolley with lifting table and holder under the subframe. Lift up the lifting table, be careful to position it correctly.
32. Remove the last 4 bolts securing the subframe.
33. Lower the subframe approx. 5 cm so that the two front clamps holding the power steering delivery pipe in place can be removed.
Remove the clamps, lower the subframe and move the lifting trolley out of the way.
34. Remove the splash plate (secured with two bolts to the transmission casing) to access the torque converter mounting on the drive plate.





35. Undo the 3 bolts securing the torque converter to the drive plate.
Rotate the plate together with the pulley.

NOTE: The crankshaft must be rotated to make all the bolts accessible.

36. Press the torque converter towards the gearbox and fit 87 92 574 Holder to keep it in place while the gearbox is removed.





37. Disconnect the ground leads.
38. Remove the torque arm with bracket.
39. Drain the transmission fluid, fit the drain plug.
Tightening torque 40 Nm (30 ft. lbs.)
40. Disconnect the oil cooler inlet and outlet hoses.
Plug the inlet and outlet passages on the transmission and also plug the hoses.
Use plug no. (10) 91 32 929 and seal no. (10) 91 32 937.





41. Loosen the left drive shaft using 87 92 616 Removing tool, drive shafts.
42. Suspend the shaft by means of a cable tie.
43. Lower the car to the floor.





44. Remove the left-hand engine pad.





45. Lower the unit approx. 100 mm so that the transmission clears the structural member.
Remove the transmission bracket from the transmission.
46. Raise the car.








47. Fit 87 92 608 Holder for single-column lift to a column jack.
Adjust and tighten the tool to the transmission as illustrated.
Use a bolt that is approx. 20 mm longer than the bolt that has been removed and a nut and bolt for the rear lifting lug.





48. Remove the remaining bolts securing the transmission to the engine.
49. Pull out and lower the transmission casing.

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

50. Lift down the gearbox from the pillar jack using an engine hoist and 87 92 442 Lifting cable while removing the lifting tool from the gearbox.