Transmission Replacement (Engine and Transmission)
Transmission Replacement (Engine and Transmission)
Special Tools
* DT-47648 /DT-47648-2/DT-47648-3/DT-47648-5 Left/DT-47648-5 Right Transmission Holder
* KM-904 Base Frame
* KM-911
* KM-924 Blanking Plugs
* KM-6001-A Engine Mount
* KM-6388 Bracket
* Graphic/Decal/Emblem Location Specifications Engine Bridge
Removal Procedure
Note: In order to ensure that the drive unit is correctly aligned when the bolts for the left engine damping block are slackened, the drive unit must be aligned with the front axle body using KM-6001-A . Instructions for attaching KM-6001-A are given in the following.
1. Remove the battery and the battery tray. Refer to Battery Tray Replacement (Service and Repair).
2. Remove the front exhaust pipe, catalytic converter and center silencer. Refer to Exhaust System Replacement (Service and Repair).
3. Install KM-6001-A to the front axle body.
* Release the 2 bolts (arrows) for the adjusting rails on KM-6001-A (1).
Note: Two pins (2 and 5) must sit in the guide holes of the front axle body.
* Insert the KM-6001-A as shown.
Tighten the 2 bolts for the adjustment rails.
Note: The guide pins must sit in the support bearings free of play.
* Twist the front support bearing (4) as far up the stop on the guide pin of the front engine mount.
Note: The guide pins must sit in the support bearings free of play.
* Twist up the rear support bearing (3) as far as the stop on the guide pin of the rear engine damping block bracket.
4. Release and disconnect the wiring harness plug for the selector lever position switch (2).
Open the lock in the direction of the arrow.
5. Release and disconnect the wiring harness plug (3) for the transmission wiring harness.
Open the lock in the direction of the arrow.
6. Disconnect the selector cable from the counterhold.
* Open the retaining clamp (1).
* Remove the selector cable (4) from the selector lever.
7. Remove the selector cable bracket.
Remove the 2 bolts (1).
8. Remove the fluid filler tube (2) with the dipstick.
Remove the nut.
9. Release the transmission at the top.
Remove the 3 bolts (1).
Note: KM-6001-A remains on the front axle body and may not be moved.
10. Remove the front frame. Refer to Front Frame Replacement (Removal) (Front Frame Replacement (Removal))Front Frame Replacement (Replacement) (Front Frame Replacement (Replacement)).
Note: Place a drain pan underneath - transmission fluid escapes. Axle shafts remain in the wheel hubs. Install the axle shafts to the underbody.
11. Remove the 2 axle shafts from the transmission. Refer to Wheel Drive Shaft Replacement (Service and Repair).
Seal the 2 apertures in the transmission with the plugs.
12. Remove the converter from the drive disc.
* Remove the 2 sealing plugs.
* Lock the drive disc with KM-911 (2).
Note: Turn the drive disc by a further 120 degrees each time.
* Remove the 3 bolts (1).
Note: Place a drain pan underneath - transmission fluid escapes. Note the allocation of the fluid cooler lines.
13. Remove the 2 fluid cooler lines (1) from the transmission.
* Remove the 2 retaining clamps (2).
* Seal the apertures in the transmission with KM-924 .
14. Remove the front engine damping block.
Remove 2 bolts (3).
15. Remove the wiring harness bracket.
Remove the bolt (1).
16. Remove the rear engine mount.
Remove the 3 bolts (2).
17. Remove the transmission venting hose from the transmission.
18. Remove the left engine mount from the engine mount bracket.
Remove the 3 bolts (1).
Note: Do not damage the wiring harnesses and attaching parts.
19. Lower the engine and the transmission with MKM-883-1 approximately 5 cm.
20. Remove the transmission from the oil pan.
* Remove the 3 M10 bolts (1).
* Remove the M10 bolt connection (2).
21. Position the transmission holder DT-47648 on KM-904 and pre-install as shown in the illustration.
* Converter housing support.
- Position on the base plate: 2
- Component: DT-47648 DT-47648-2 (4)
* Transmission housing support
- Position on base plate: 14
- Component: DT-47648 DT-47648-3 (2)
* Support with rear the transmission swivel arm.
- Position on base plate: A
- Component: DT-47648 DT-47648-5 Left (1)
* Support with the front transmission swivel arm
- Position on base plate: F
- Component: DT-47648 DT-47648-5 Right (3)
Note:
* It is important that the manufacturer instructions for transmission holder DT-47648 are followed.
* Before placing in position slacken all bolt connections of the swivel arms and supports as far as the base plate. Adjust the supports for the converter housing and transmission housing using the spindles until they are as low as possible.
22. Install the transmission holder DT-47648 to the transmission.
* Align the transmission holder DT-47648 under the transmission.
* Install the 2 swivel arms (1) to the transmission.
Note: 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.
* Position the supports for the converter housing and the transmission housing on the transmission.
* Twist up the spindles (2).
* Tighten the bolt connections for the supports.
23. Remove the transmission.
* Remove the 2 M12 bolts (1).
* Press the transmission off the engine and slowly lower the hydraulic jack.
* Install KM-6388 (1).
24. Secure the torque converter so it does not fall out.
Note: Do not damage the attaching parts when putting the transmission down.
25. If required, remove the transmission from the transmission holder DT-47648 .
26. When replacing the transmission:
* Drain the oil cooler as much as possible.
* Blow the low-pressure compressed air through the oil cooler.
* Blow the low-pressure compressed air in both directions through the fluid cooler lines from the connections.
* Transfer the attaching parts.
Installation Procedure
Note: It is important that the manufacturer instructions for DT-47648 are followed. Before installing the transmission, thinly coat the centering seat (arrow) for the converter in the crankshaft with grease. When replacing the transmission, ensure that the two guide bushings (1) sit in the engine flange.
1. If required, install the transmission to the transmission holder DT-47648 .
2. Inspect the converter centering journal (3) for fretting.
Clean if necessary.
3. Measure the distance between the converter connecting threads and the mating surface of the transmission housing with a caliper gage (2).
approximately 12 mm
4. Recut the thread (arrows) in the converter.
5. Remove KM-6388 .
6. Raise the transmission with the hydraulic jack and the transmission holder DT-47648 and align it.
Note: Ensure it is perfectly seated. Do not damage wiring harnesses and attaching parts.
Position the transmission evenly on the engine.
Caution: Refer to Fastener Caution (Fastener Caution).
7. Fasten the transmission to the engine with 2 bolts.
Tighten the 2 M12 bolts (1) to 60 Nm (44 lb ft).
8. Remove the transmission holder DT-47648 from the transmission.
* Remove the 2 bolts.
* Lower the hydraulic jack with the transmission holder DT-47648 and pull out.
9. Fasten the transmission at the bottom.
* Install the transmission on fluid sump.
* Tighten 3 M10 bolts (1).
Tighten the 3 M10 bolts to 40 Nm (30 lb ft).
* Tighten the bolt connection (2).
Tighten bolt connection to 40 Nm (30 lb ft).
10. Install the converter to the drive disc.
* Lock the drive disc with KM-911 (2).
Note: Insert the bolts with locking compound. Turn drive disc by a further 120 degrees each time.
* Tighten 3 bolts (1).
- Stage 1: Tighten 3 bolts evenly to 20 Nm (15 lb ft).
- Stage 2: Tighten 3 bolts to 45 Nm (33 lb ft) plus 20 degrees, plus 25 degrees.
* Remove KM-911.
11. Install the 2 covers to the transmission.
12. Install the engine mount to the transmission at the front.
Tighten the 2 bolts (1) 80 Nm (59 lb ft).
13. Install the rear engine damping block to the transmission.
Tighten the 3 bolts (2) 80 Nm (59 lb ft).
14. Install the wiring harness bracket.
Tighten the bolt (1).
15. Install the axle shafts in the transmission. Refer to Wheel Drive Shaft Replacement (Service and Repair).
Note: Note the allocations.
16. Install the oil cooler lines to the transmission.
Note: Fluid cooler lines must be heard to engage.
Use 2 NEW O-rings (1).
17. Raise the engine and the transmission with MKM-883-1 and align.
18. Install the left engine mount to the engine mount bracket.
Note: Do not tighten the 3 bolts yet.
Install the 3 bolts (1).
Note: When installing the front axle body, ensure that the support bearings with KM-6001-A sit properly in the guide pin of the front engine damping block and the rear engine damping block bracket. If necessary: correct installation position of engine and transmission using MKM-883-1 .
Note: Do not yet install front exhaust pipe, catalytic converter, center muffler, battery support and battery.
19. Install front frame. Refer to Front Frame Replacement (Removal) (Front Frame Replacement (Removal))Front Frame Replacement (Replacement) (Front Frame Replacement (Replacement)).
20. Fasten the left engine mount.
Tighten the 3 bolts (1) to 55 Nm (40 lb ft).
21. Secure the transmission at the top.
Tighten the 3 bolts (1) to 60 Nm (44 lb ft).
22. Install the selector cable bracket.
Tighten the 2 bolts (1) to 20 Nm (15 lb ft).
Note: Use new seal ring.
23. Install the fluid filler tube (2) with dipstick.
Tighten the nut.
24. Connect the transmission venting hose to the transmission.
25. Install the selector actuation cable.
* Install to the selector actuation cable bracket.
* Install to the actuation lever.
26. Connect and lock the wiring harness plug for the transmission wiring harness.
27. Connect and lock the selector lever position switch wiring harness plug.
28. Adjust the range selector cable. Refer to Range Selector Lever Cable Adjustment (Adjustments).
29. Install the battery tray and battery. Refer to Battery Tray Replacement (Service and Repair).
30. Remove KM-6001-A .
31. Install the front exhaust pipe, catalytic converter and center silencer. Refer to Exhaust System Replacement (Service and Repair).
32. Inspect the transmission fluid level. Refer to Transmission Fluid Check (Transmission Fluid Check).
33. For programming procedures, refer to Control Module References (Programming and Relearning).