AB B. Replacing Rear Cover
Special tools: 999 5517Setting steering wheel AB B1
Loosen the lever for the steering wheel adjustment. Push the steering wheel forward and upward and lock it in this position.
Position the wheels in a straight forward direction. Shift the transmission into N (neutral) position. Disconnect the negative battery terminal.
Lock the steering wheel so it cannot turn.
Note!
Ensure the steering wheel is NOT turned. This may cause damage to the SRS contact reel when performing the repair.
Remove AB B2
Remove:
- mass air flow connector,
- air cleaner housing assembly with fresh air duct, - cover the fresh air inlet hose with a clean rag. In the following step eye protection must be worn
Blow with compressed air in the area around where the cover is going to be split from the transmission case. This is to prevent debris from falling into the case.
Turbos only:
Remove the turbocharge control valve (TC) from the air cleaner housing.
Securing clutch drum before removing rear cover AB B3
Note!
In this step the picture shows the drum without the transmission rear cover. This is to better illustrate how to insert the screw driver to lock the drum and prevent it from walk out when the rear cover is removed as per AB B13 later in this method.
Remove the vehicle speed sensor (VSS).
Insert a screwdriver 125 mm (6") with a shank approx. 3 mm (0.118") in the hole for the speed sensor and wedge the clutch drum as per illustration.
Note!
Do not use the hammer to wedge the screwdriver in between the case and the drum. Push only by hand on the screwdriver.
AB B4
Removing throttle bobbin
Cars with turbo charger:
Remove the cover over the throttle bobbin (arrow).
Disconnect the throttle cable from the bobbin and the bracket.
Remove the air charge pipe between the turbo charger and the intercooler (arrow).
Removing air charge and oil cooler line AB B5
Turbos only
Remove:
- upper air charge pipe/hose from the throttle body,
- upper transmission oil cooler line on the radiator.
Cars with EGR AB B6
Remove the hoses from the controller on the fan shroud bracket.
Removing ground strap AB B7
Remove:
- ground strap from the cowl,
- bolt from the torque arm.
Removing wheel AB B8
Remove:
- left front wheel,
- upper nut for the sway bar link on strut,
- nuts for the wheel well liner and pull back/up,
Note!
Do not pull or bend the well liner excessively.
Removing air box to guide AB B9
Air guide, two bolts (Arrows).
Push air guide slightly forward to release tab from the radiator.
Splash guard on early M/Y:s.
The clamp for the negative battery cable on the sub-frame. (M/Y 1994 and up)
Removing attachment bolt AB B10
Remove attachment bolt for the wire duct/conduit on the sub-frame.
Loosen up the clamp for the exhaust pipes behind the catalyst.
Failing to loosen the clamp may result in leakage at the heater/pipe flange.
Note!
The clamp does not have to be removed.
Removing bolt attaching the universal joint AB B11
Note!
Mark U-joint in the relation to steering rack pinon shaft
Lock pin.
Remove the bolt attaching the universal joint to the steering rack, then push the joint upward off the steering rack.
Drain the oil out of the transmission.
Note!
Ensure the steering wheel does not turn so that the contact reel for the SRS is altered.
Lowering the sub-frame AB B12
Loosen the right side mounting bolts for the sub-frame 3 turns.
Do not use an impact wrench to loosen right side subframe bolts. Bolts may come out too tar.
Support the sub-frame with a transmission jack and remove the two left side attachment bolts.
Remove two bolts for the support bracket for the left rear sub-frame attachment (arrows).
Install tool 999 5517 and tighten to 20 Nm (15 lbs), turndown the flange nuts to 25 mm (1.0") from the bolt head.
Carefully lower the transmission jack to where the sub- frame rests on the flange nuts.
Remove the transmission jack.
Carefully turn the two flange nuts counter clockwise until the transmission cover can be removed without interfering with the frame rail.
Removing cover AB B13
Break loose the four 12 mm plugs for the pressure ports and the TORX plug on the cover. Do not remove the plugs.
Remove all bolts from the cover.
Carefully tap on the cover with a plastic hammer to loosen it from the case.
Then carefully pull and turn at the same time, the cover back and forth to remove it from the clutch drum making sure the drum stays in the transmission.
Secure drum AB B14
Important:
Ensure the drum is still secured and cannot move.
Check if the outer bearing race is still in the cover, one should see the needles in the trust bearing (arrow).
A new outer race will come with the new cover.
Carefully clean the contacting gasket surface on the case not damaging the surface. Do not use a razor blade.
Before installing the cover AB B15
Measure the distance between the gasket surface and the clutch drum as shown in the illustration. The measurement must be 37-39 mm (1.511-1.590")
In the measurement is more then 39 mm (1.590") one or more of the clutch or steel discs is out of position.
How to correct
Turn the drum back and fourth and tap carefully on the center pant of the drum with a rubber mallet. Several tries might be needed to successfully seat the drum correctly.
Installing new O-rings AB B16
Note!
Secure the drum with a wire or similar so it cannot slide out.
Check if the outer bearing race is still in the cover, one will se the needles in the trust bearing. New race will come with the new cover.
Clean the containing gasket surface on the case carefully, not damaging the surface. Do not use razor blade.
Install new O-rings (four supplied).
New cover AB B17
Caution!
Make sure no gasket material enters the oil channels. (arrows)
Apply a thin layer of liquid gasket P/N 1161409 on the gasket surface. Make sure gasket material is spread out around all bolt holes.
Torque bolts crosswise:
- M6: 10 Nm
(7 lbs)
- M8: 25 Nm
(18 lbs)
Installing the cover AB B18
Make sure that no dowel pin came out with the old cover. If so it has to be transferred back to the transmission case.
The new trust bearing race using petroleum jelly.
Lubricate the seal rings and the grooves generously with Petroleum jelly. This will help keep the seal rings secured while installing the cover.
Install the cover carefully so that the seal rings enter the drum without binding. The cover will seat against the case when installed correctly.
Install all pressure port plugs and the TORX plug.
Torque bolts crosswise, M8 25Nm (18 lbs), M6 10 Nm (7 lbs).
Reattaching sub frame AB B19
Note!
New bolts must be used. Grease the bolt threads.
Carefully raise subframe with a transmission jack until it contacts the frame rail.
Remove the two special tools 999 5517.
Install the new M14 bolts and the rear support plate. Install the two support plate bolts loosely.
Torque subframe bolts (four) to 105 Nm (77.5 lbs) + 120.
Torque bolts for the support plate to 50 Nm (37 lbs)
Installing universal joint to steering gear AB B20
Note!
Make sure the markings on the U-joint and the pinon shaft correspond.
Install universal joint to steering gear. Tighten to 20 Nm (15 lbs).
Lock spring.
Installing attachment bolt AB B21
Re-tighten the clamp for the exhaust pipe behind the catalytic converter.
Install attachment bolt for the wire duct/conduit on the subframe.
Installing air guide AB B22
Install:
- Clamp for the negative battery cable.
- splash guard on early M/Y:s,
- air guide, two torx (27 screws).
Re-attach sway bar link AB B23
Re-attach sway bar link and torque the nut 50 Nm (37 lbs).
Install:
- wheel well liner with plastic nuts,
- left front wheel, torque 110 Nm (81 lbs)
Installing bolt and nut for torque arm AB B24
Install bolt and nut for torque arm/torque rod.
Note!
Use new screw and locknut.
Replacement part number lock nut P/N:
- M8 (on early version) p/n 948645-7
- M10 (on late version) p/n 971098-9
Note!
On later version the lock nut is installed.
Tighten to:
- M8: 18 Nm (13 lbs) + 120
- M10: 35 Nm (26 lbs) + 90
Installing air charge pipe/hose AB B25
Install:
- upper transmission oil cooler line on the radiator. Use a new lock clip.
- air charge air pipe/hose to the throttle body.
Cars with EGR AB B26
Install the hose(s) from the controller on the fan shroud bracket.
Installing air charge pipe (turbos only) AB B27
Install:
- the cover over the throttle bobbin (arrow),
- air charge pipe between the turbocharger and the intercooler (arrow).
Installing air cleaner house assembly AB B28
Vehicle speed sensor (VSS) torque screw 10 mm (6 lbs). Remove rag from inlet hose.
Install air cleaner house assembly with fresh air duct.
Install air mass sensor connector.
Turbos only:
Install the turbo charger valve (TC) to the air cleaner housing (only turbocharged engines).
Note!
Make sure the hoses for the TC valve are not pinched while the air cleaner housing is mounted in the bracket.
Filling up transmission AB B29
The transmission must be filled with DEXTRON III/MERCON transmission fluid, 3,5 liters (3.7 qt). Changing oil, Section 4(43), Automatic gearbox AW50-42, 850 1992-.
Test drive and check function of the transmission and that no leakage is present after test drive.
Note!
It may be required to add/remove transmission fluid when the fluid has been warmed up after the test drive. Do not overfill the transmission.