Transmission Replacement (Transmission Only)

Transmission Replacement (Transmission Only)

Special Tools
* KM-313 Sliding Hammer
* OTC 1726 /KM-412-31-2/KM-412-A Engine Overhaul Stand
* KM-460-B Axle Shaft Remover
* KM-6003 Remover
* KM-6349 Fixing Rod

Removal Procedure





Note: Engine with the automatic transmission removed.

1. Remove the coolant return hose and the throttle valve pre-heating (1) from the coolant expansion tank.

* Release the clamp.
* Remove from the bracket.




2. Remove the upper radiator hose (1) from the thermostat (2).
Release the clamp.
3. Remove the lower radiator hose from the coolant pump.

* Release the clamp.
* Remove from the bracket.




4. Remove the refrigerant lines (1) from the compressor.
Remove the bolt (2).




5. Disconnect the 3 wiring harness plugs.

* Compressor (1)
* Manometric switch, condenser (2)
Remove the wiring harness.
* Temperature sensor, radiator (3)




6. Remove the 2 transmission fluid lines (1) from the automatic transmission.
Lever off the 2 retaining clamps (2) from the quick coupling.




7. Remove the cooling module (1).
Remove from the lower radiator brackets.
8. Place a drain pan underneath.




9. Remove the right-hand frame.

* Remove the frame with KM-460-B (1) from the differential gear.
* Seal the opening in the differential with a sealing plug.




10. Remove the left-hand frame.

* Remove the frame with KM-313 and KM-6003 (1) from the differential gear.
* Seal the opening in the differential with sealing plug.




11. Remove the oil dipstick guide tube (2).

* Remove the bolt (1).
* Remove the oil dipstick guide tube upward.

12. Remove the wiring harness plug of the catalytic converter control oxygen sensor.

* Disconnect the wiring harness connector.
* Remove from the bracket.




13. Remove the drive belt.

* Apply tension to the drive belt tensioner in the direction of the arrow at the projection (1) and lock with KM-6349 (2).
* Remove the drive belt.

14. Remove the exhaust manifold heat shield.
Remove the 3 bolts.




15. Remove the bracket for the catalytic converter (1) from the cylinder block.
Remove the 2 bolts (2, 3).




16. Remove the exhaust manifold.
Remove the 9 nuts (1).




17. Remove the compressor.
Remove the 3 bolts (1).




18. Remove the coolant pipe (1) between the thermostat housing and the oil filter housing.

* Remove the 2 bolts (2).
* Draw out of the oil filter housing.




19. Remove the coolant pipe (1) from the coolant pump.

* Remove the 2 bolts (2).
* Push the coolant pipe into the oil filter housing.




20. Remove the oil filter housing (3).

* Release the coolant pipe (1) and push into the oil filter housing.
Remove the bolt (2).
* Remove the 4 bolts (4).




21. Remove the intake manifold support (2).

* Disconnect the wiring harness plug of the catalytic converter control oxygen sensor.
* Remove the wiring harness plug (1) from the bracket.
* Remove the 2 bolts (3).




22. Disconnect the alternator from the power supply.
Remove the 2 nuts (1, 2).
23. Remove the alternator.
Remove the 2 bolts (3, 4).




24. Remove the negative cable (1) from the starter.
Remove the nut.
25. Remove the 2 positive cables (2) from the starter.
Remove the 2 nuts.




26. Remove the starter.

* Remove the wiring harness plug for the oxygen sensor of the catalytic converter control from the bracket.
* Remove the 2 bolts (1) and (2).




27. Install OTC 1726 KM-412-31-1 (1).

Tighten the 3 bolts (2) to 5 Nm (44 lb in).




28. Install OTC 1726 (1).

Tighten the 3 bolts to 5 Nm (44 lb in).

29. Attach the engine up to the workshop crane.
Install the holding ropes to the engine transport shackles.




30. Remove the front engine mount.
Remove the screw connection (1).
31. Remove the rear engine mount.
Remove the screw connection (2).
32. Lift the motor away from the front axle body.
33. With the aid of an assistant, install the engine on the engine overhaul stand OTC 1726 KM-412-A.
Remove the holding ropes from the engine transport shackles.




34. Remove the gearshift cable bracket (1) from the transmission.
Remove the 2 bolts (2).





Note: Lock the torque converter with the appropriate counterstay (1).

35. Remove the torque converter from the drive disc.

* Remove the 2 sealing plugs.
* Turn the engine towards the torsional vibration damper until the relevant screw is accessible.
* Remove the 3 bolts.





Note: One bolt remains as a retaining device.

36. Remove the transmission (1) from the engine.
Remove the 7 bolts.

Note: Torque converter must remain in the transmission.

37. Remove the gearbox.

* Attach the holding ropes.
* Hitch the gearbox up to the workshop crane.

Note: Ensure that installed parts and the wiring harnesses are undamaged.

* Remove the bolt.

Installation Procedure




1. Measure the resistance, torque converter in the transmission.

* Measure with measuring device (1).
* Distance: approximately 12 mm




2. Coat the centering seat (arrow) for the torque converter in the crankshaft with grease.
3. Check the correct seating of the 2 guide bushes (1) in the engine flange.




4. Cut thread (arrows) in the torque converter.
5. Install the gearbox.

* Install the gearbox up to the workshop crane.
* Install the transmission to the engine.
* Screw in the bolt.
* Remove the workshop crane.
* Remove the holding ropes.

Caution: Refer to Fastener Caution (Fastener Caution).

6. Install the transmission to the engine.

* Install the transmission to the cylinder block.

Tighten the 4 bolts to 60 Nm (44 lb ft).

* Install the transmission to the oil pan.

Tighten the 3 bolts to 40 Nm (29 lb ft).

Note: Insert bolts with the locking compound. Insert the bolts in two stages.

7. Install the torque converter to the drive disc.

* Tighten the 3 bolts.

- Tighten the 3 bolts to 20 Nm (15 lb ft).
- Tighten the 3 bolts to 45 Nm (33 lb ft) plus 30 degrees.

* Install the covers.

8. Attach the engine up to the workshop crane.
Install the holding ropes to the engine transport shackles.
9. With the aid of an assistant, remove the engine from the engine overhaul stand OTC 1726 KM-412-A.
Raise the engine carefully.
10. Install the rear engine mount, front frame.

Tighten the screwed joint to 55 Nm (40 lb ft).
Use NEW nuts.
11. Install the front engine mount to the front frame.

Tighten the screwed joint to 55 Nm (40 lb ft).
Use new nuts.
12. Remove OTC 1726 KM-412-31-1 and OTC 1726 KM-412-31-2 from the cylinder block.
Remove the 6 bolts.
13. Install the alternator.

Tighten the 2 bolts to 35 Nm (25 lb ft).

14. Install the starter.

Tighten the 2 bolts to 25 Nm (18 lb ft).
Connect the wiring harness plug for the oxygen sensor of the catalytic converter control to bracket.
15. Install the starter wiring harness.

Tighten the 2 nuts to 12.5 Nm (110 lb in).

16. Install the negative cable.

Tighten the nut to 5 Nm (44 lb in).

17. Connect the generator wiring harness.

Tighten the 2 nuts to 7 Nm (62 lb in).

18. Install the intake manifold bracket.

Tighten the 2 bolts to 8 Nm (71 lb in).

* Connect the wiring harness plug to the bracket.
* Connect the wiring harness plug for the catalytic converter control oxygen sensor.

19. Clean the sealing surface.
20. Replace the 4 coolant pipe seal rings.

* Remove the 2 coolant pipes from the oil filter housing.
* Insert the 2 coolant pipes in the oil filter housing.

21. Install the oil filter housing.

Tighten the 4 bolts to 25 Nm (18 lb ft).

* Install the 3 new gaskets.
* O-rings with white silicone grease

22. Install the coolant pipe to the coolant module.

* Remove the coolant pipe out from the oil filter housing.
* Install the coolant pipe to the oil filter housing.

Tighten the bolt to 25 Nm (18 lb ft).

23. Install the module to the coolant pipe manifold.
Remove the coolant pipe out from the oil pump housing.

Tighten the 2 bolts to 8 Nm (71 lb in).

24. Remove the coolant pipe, oil filter housing to the thermostat housing.

* Replace the 2 gaskets.
* Push into the oil filter housing.
* Install the thermostat housing.

Tighten the 2 bolts to 8 Nm (71 lb in).

25. Install the compressor.

Tighten the 3 bolts to 22 Nm (16 lb ft).

26. Clean the sealing surface.
27. Install the exhaust manifold with the catalytic converter.

* Use a new gasket.

Tighten the 9 new nuts to 20 Nm (15 lb ft).

* Install the bracket to the cylinder block.

Tighten the 2 bolts to 20 Nm (15 lb ft).

28. Install the heat shield.

Tighten the 3 bolts to 8 Nm (71 lb in).

Note: Be careful of the wiring harness bracket.

29. Install the wiring harness plug of the catalytic converter control oxygen sensor.

* Connect the wiring harness plug.
* Install the wiring harness plug.

30. Install the dipstick guide tube.

* Use a NEW gasket.
* Insert the guide tube into the oil pan.

Tighten the bolt to 8 Nm (71 lb in).




31. Install the left-hand mount.

* Install the new circlip (1) to the mount.
* Lubricate the teeth and the bearing points with engine oil.
* Push the mount into the gearbox until the circlip engages.

32. Install the right-hand mount.

* Install the new circlip to the mount.
* Lubricate the teeth and the bearing points with engine oil.
* Push the mount into the gearbox until the circlip engages.

33. Place the cooling module in position.





Note: Observe the correct assignment.

34. Install the oil cooling lines to the transmission.
Use the 2 NEW O-rings (1).
35. Connect the 3 wiring harness plugs.

* Temperature sensor, radiator
* Compressor
* Manometric switch, condenser
Install the wiring harness.

36. Attach the refrigerant line to the compressor.
Use a new gasket.

Tighten the bolt to 20 Nm (15 lb ft).

37. Attach the lower radiator hose to the radiator.
Install the bracket.

Tighten the clamp

38. Attach the upper radiator hose to the thermostat.
Tighten the clamp.
39. Attach the coolant return hose, throttle valve pre-heating to the coolant expansion tank.
Install the bracket.

Tighten the clamp.

40. Inspect and correct the transmission fluid level. Refer to Fluid Capacity Specifications (Capacity Specifications).