Transmission Replacement (Transmission Only)

Transmission Replacement (Transmission Only)


Special Tools
* KM-569-A Plug Remover
* KM-6001-A Engine Mount
* MKM-883-1 Engine Bridge
* DT-47648 Transmission Holder
* KM-904 Base Frame



Removal Procedure

Important: If the transmission is replaced, the following parts must be transferred:


1. Connection piece for clutch actuation.

2. Engine damping block bracket.

3. Shift Bowden cable bracket.




1. Remove the battery tray. Refer to Battery Tray Replacement (Service and Repair)
2. Place a drain pan underneath.




3. Disconnect the wiring harness plug, backup lamp switch (1).
4. Remove the clutch pressure hose (4) from the connection piece (2).

* Open the retaining clamp (3).
* Remove the clutch pressure hose.
* Close the retaining clamp.





5. Remove the selector lever link (1) from the transmission cover (2).

* Press in the retaining spring (arrow) of the hollow pin.
* Lever out roll pin with KM-569-A .





6. Release the transmission at the top.
Remove the 4 bolts (arrows).





Notice: Refer to Fastener Notice (Fastener Notice)

7. Attach KM-6001-A to the front frame.

* Remove the 2 bolts (arrows) for the adjustment rails on KM-6001-A (1).

Important: Two journals (2) and (5) must sit flush in the guide holes of the front frame.


* Insert KM-6001-A as shown.

Tighten the 2 bolts for the adjustment rails.


Important: The guide pins must sit in the support bearings with no play.


* Adjust the front support bearing (4) until in contact with the guide pin of the front engine damping block.

Important: The guide pins must sit in the support bearings with no play.


* Adjust the rear support bearing (3) until in contact with the guide pin of the rear engine damping block bracket.

8. Remove the front frame. Refer to Front Frame Replacement (Replacement) (Front Frame Replacement (Replacement))Front Frame Replacement (Removal) (Front Frame Replacement (Removal)) .

Important: Axle shafts remain in the wheel hubs.


9. Remove the 2 axle shafts from the transmission. Refer to Wheel Drive Shaft Replacement (Service and Repair) .

* Attach the axle shafts to the vehicle underbody.
* Seal the 2 openings for the 2 axle shafts with a plug.






Important: Do not damage wiring harnesses and attaching parts.


10. Remove the transmission from the left engine damping block.
Remove the 3 bolts (1).
11. Lower the engine and transmission on the left-hand side.
Use MKM-883-1 .




12. Remove the front engine damping block bracket.
Remove the 2 bolts (1).
13. Remove the rear engine damping block bracket.
Remove the 3 bolts (2).




14. Place the transmission holder DT-47648 on KM-904 and pre-install as shown in the illustration:

1. DT-47648 (4)

* Position on Base Plate-2
* Designation-Clutch housing support

2. DT-47648 (2)

* Position on Base Plate-14
* Designation-Transmission housing support

3. DT-47648 (1)

* Position on Base Plate-A
* Designation-Support with rear transmission swivel arm

4. DT-47648 (3)

* Position on Base Plate-F
* Designation-Support with rear transmission swivel arm







Important: It is essential to follow the manufacturer's instructions for transmission holder DT-47648 .



Important: Before placing in position, slacken all bolt connections of the swivel arms and supports as far as the base plate. Adjust the supports using the spindles until they are as low as possible.


15. Attach the transmission holder DT-47648 to the transmission.

* Place the transmission holder DT-47648 with supports in position under the transmission.
* Tighten the bolt connections of the supports
* Attach the swivel arm (1) and (2) to the transmission.

Important: Align the swivel arms so that as little leverage as possible is created.


* Tighten the bolt connections of the swivel arms starting from the transmission and going as far as the base plate






Important: Do not damage attaching parts when putting the transmission down.


16. Remove the transmission.

* Remove the 3 bolts (2), transmission to oil pan.

Important: Note differing bolt lengths.


* Remove the 3 bolts (1) and (3), transmission to cylinder block.

Important: Do not damage attaching parts.


* Pry the transmission away from the engine.
* Carefully lower the transmission with the hydraulic jack and extend the hydraulic jack.

17. With the aid of an assistant, remove the transmission from DT-47648 .

* Remove the 2 bolts.
* Put the transmission down carefully.




Installation Procedure


Notice: Refer to Fastener Notice (Fastener Notice) .

1. With the aid of an assistant, attach the transmission to DT-47648 . Tighten the 2 bolts.

Important: Ensure that no cables and brackets get trapped between the transmission and engine.



Important: Ensure it is seated perfectly.


2. Install the transmission with DT-47648

* Raise the transmission and align it.
* Place the transmission so that it is in even contact with the engine.





3. Install the transmission.
Install the wiring harness bracket with the front bolt.

* Tighten the 3 transmission to cylinder block bolts (1) and (3) to 60 N.m (44 lb ft) .
* Tighten the 2 transmission to oil pan bolts (2) to 40 N.m (30 lb ft) .


4. Remove the transmission holder DT-47648 from the transmission.

* Remove the 2 bolts.
* Lower and extend the hydraulic jack.


Important: Do not damage wiring harnesses and attaching parts.


5. Raise the engine and transmission on the left hand side.
Raise with MKM-883-1 .





Important: Do not tighten bolts yet.


6. Attach the transmission to left hand engine damping block.

Tighten the 3 bolts (1) to 80 N.m (59 lb ft).





7. Install the front engine damping block bracket.

Tighten the 2 bolts (1) to 80 N.m (59 lb ft).

8. Install the rear engine damping block bracket.

Tighten the 3 bolts (2) to 80 N.m (59 lb ft).

9. Install the 2 axle shafts to the transmission. Refer to Wheel Drive Shaft Replacement (Service and Repair) .

Important: Do not detach MKM-883-1 yet.


10. Install the front frame. Refer to Front Frame Replacement (Replacement) (Front Frame Replacement (Replacement))Front Frame Replacement (Removal) (Front Frame Replacement (Removal)) .




11. Attach the transmission to left hand engine damping block.

Tighten the 3 bolts (1) to 55 N.m (41 lb ft).

12. Remove KM-6001-A from the front frame.




13. Fasten the transmission at the top.

Tighten the 4 bolts (arrows) to 60 N.m (44 lb ft).





14. Attach the selector lever link (1) to the transmission cover (2).
Insert a new roll pin (arrow).

* Coat the roll pin with grease.
* Depress the roll pin until retaining spring engages.





15. Connect the wiring harness plug for the reversing lamp switch (1).

Important: The clutch pressure hose must audibly engage.


16. Attach the clutch pressure hose (3) to the connection piece (2).
17. Inspect for correct transmission fluid level. Refer to Transmission Fluid Check (Transmission Fluid Check) .
18. Adjust the transmission selector lever link. Refer to Selector Lever Link Adjustment (Adjustments) .
19. Bleed the hydraulic clutch actuation. Refer to Hydraulic Clutch Bleeding (Service and Repair) .
20. Install the battery tray. Refer to Battery Tray Replacement (Service and Repair) .
21. For reprogramming procedures, refer to Control Module References (Programming and Relearning) .
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