Removal

Special Tools
- Mobile Jack tool No. 998 5972, or equivalent
- Lifting Beam tool No. 999 5006, or equivalent
- Hook tool No. 999 5186, or equivalent
- Puller tool No. 999 5259, or equivalent
- Lifting Hook tool No. 999 5460, or equivalent
- Disconnecting tool No. 999 5462, or equivalent
- Fixture tool No. 999 5463, or equivalent
- Seal Plug tool No. 999 5488, or equivalent
- Fork Jack tool No. 999 5534, or equivalent
- Counterhold tool No. 999 5540, or equivalent
- Counterhold tool No. 999 5561, or equivalent
- Protective Sleeve tool No. 999 5562, or equivalent
- Support tool No. 999 5563, or equivalent
- Universal Fixture tool No. 999 5972, or equivalent

- Refer to special tool section for additional tool information.

1. Preparations:

NOTE: Avoid skin contact with transmission fluid.





2. Remove:
- Battery
- Battery Shelf
- Air cleaner (ACL) housing complete with intake manifold.
- Remove turbocharger (TC) control valve from ACL housing.





3. Remove:
- Throttle pulley cover.
Unhook throttle cable from control pulley and bracket
- Charge air pipe (assembly with hose) between the turbocharger and the charge air cooler (CAC).
Remove the bracket at the torque arm support.
Reinstall stay and tighten nut.
- Air intake pipe (from ACL) to turbocharger.





4. Disconnect the charge air pipe (1) to the throttle body (TB)
- Hold the lower pipe to the charge air cooler (CAC) (2) to the side with a tie strap.
- Disconnect the upper engine oil cooler hose (3) from the radiator.





5. Remove transmission cable and connector
- Remove:
Transmission cable from transmission
Connector from transmission. Remember rubber seal.
Clamps to the cable harness and ground lead on the transmission and sub-frame.
- Unhook the cable conduit from the transmission.
- Detach the H02S connector/connectors from the bracket on the transmission.
Disconnect connectors.





6. Remove the following pipes to the transmission oil cooler:
1. The inlet pipe at the cooler upper quick-release connector.
2. The return pipe at the transmission.
- Remove oil dipstick pipe.
- Seal all openings with plastic plugs.

NOTE: Cars with EGR Exhaust Gas Recirculation System: Detach hoses from the converter.





7. Remove screws between transmission-engine and transmission-starter motor (5 x)
- Lift radiator expansion tank from mounting and let it lie loose.





8. On Left-hand drive models: Remove lower steering shaft joint
- Turn the steering wheel so that the screw/nut to the lower steering shaft joint is as accessible as possible in the passenger compartment and in the engine compartment.
Remove the ignition key so that the steering wheel is locked in that position.
- Remove the nut and screw from the joint in the passenger compartment.
Remove the joint from the steering shaft.
- Remove screw and nut from the joint in the engine compartment. Press joint off steering gear. Remove joint.

NOTE:
- The steering gear position must not be changed so that the pinion is turned a revolution.
- The SRS-system contact reel can be damaged if this occurs.





9. Remove connecting components. Install lifting beam
- Disconnect ground strip from firewall.
- Remove screws on upper torque rod - torque arm at engine.
- Install lifting fork 999 5534 onto the engine torque rod.





10. Install lifting beam and lifting hook
- Install:
Lifting beam 999 5006 on fender edges.
Locate the beam directly above the eye on the lifting fork.
Lifting hook 999 5460.

NOTE: When using the early version lifting hook (A), hook 999 5186 should be connected between the lifting fork and the lifting hook. Illustration (B) displays the late version lifting hook.

- Lift hook approximately 5 mm (0.196 inch) to relieve engine pads slightly.
- Measure and record the distance between lifting beam and sparkplug cover.





11. Remove:
- Front wheels
- ABS sensors from stub axles on both sides.

NOTE: Do not disconnect connector.

Remove:
- Brackets from brake pipes and ABS wiring (both sides).
Detach the brackets and let them hang loose.
- Links to anti-roll bar on both sides.
- Remove screws to left engine mounting.





12. Remove:
- The front plastic nuts to the left-hand side fender liner
- Front Splash guard, both screws.
Press the splash guard forwards to free the guides at the rear edge.
Free splashguard at front edge.
Remove it
- Drive shaft nuts on both sides.
Use counter hold 999 5540. Remove nuts.
- Detach drive shaft end in the hub.
- Knock the end of the drive shaft approximately 10-15 mm (0.393-0.590 inch) into the hub.
Use a rubber or copper mallet.

Only Right Hand Drive Models:





13. Remove collision protection over the steering gear
- Fastened with two screws.





14. Remove lower steering shaft joint
- Turn the steering wheel so that the screw/nut to the lower steering shaft joint is as accessible as possible in the passenger compartment and in the engine compartment.
Remove the ignition key so that the steering wheel is locked in that position.
- Remove the nut and screw from the joint in the passenger compartment.
Remove the joint from the steering shaft.
- Remove screw and nut from the joint in the engine compartment.
Press joint off steering gear.
Remove joint.

NOTE:
- The steering gear position must not be moved so that the pinion is turned one revolution.
- The SRS-system contact reel can be damaged if this occurs.

On Right And Left Hand Drive Models





15. Remove:
- Tie rods from stub axle. Use puller 999 5259.
Unhook the stay from the stub axles
- Control arm/ball joint from stub axle (both sides).
Install protective sockets 999 5562.





16. On the right-hand side: Install holder for control arm
- Install holder 999 5563 to hold down the control arm.
- Press the drive shaft in to its inner position.
Turn and fold out spring strut.
Remove the drive shaft from the hub.





17. Remove right drive shaft
Remove:
- Drive shaft bearing cap
- Drive shaft.
Carefully pull it straight out from the transmission so that sealing ring is not damaged.
- Clean off traces of metal adhesive from the spline joint (hub-drive shaft).





18. Disconnect/remove other components
Remove:
- The charcoal filter holder with hoses (A) from the subframe.
Cut off tie straps to hoses.
Hang up reservoir in bodywork.
- Connector (B) to the accelerometer
- (Remove) the cable conduit (c) mounting screw on the sub-frame.
Unhook conduit from sub-frame
- Exhaust pipe clamp behind three-way catalytic converter.





19. Drain the oil
Remove:
- Screw for the oil pipe bracket in front edge of the frame
- The two bolts securing torque rod mounting support on transmission.
- Drain transmission oil.
- Remove front engine pad screw.

NOTE:
- The oil should only be changed if the transmission or the oil is being changed.
- Tighten the drain plug to 40 Nm (29.5 ft 1b).

WARNING: Oil may be extremely hot.





20. Remove sub-frame from car
- Position mobile jack 998 5972 to support the left-hand side of the sub-frame, slight pressure.
- Remove the sub-frame support brackets screws (A) in the bodywork (both sides).
- Unscrew the two screws (B) between the frame and the bodywork (right-hand side) maximum 5 turns.
- Remove the screws (c) on the left-hand side.
- Lower sub-frame.
Remove:
- Vibration damper (D) on the bevel gear
- steering limiter (E) from the sub-frame.





21. Remove left drive shaft
- Turn and fold out spring strut.
- Tap in drive shaft end.
- Use a rubber or copper mallet.
- Withdraw drive shaft from hub
- Remove drive shaft from transmission.
- Use jimmy bar tool No. 999 5462 between transmission and inside of drive shaft.

NOTE: Take care that the seal rings in the transmission and the boot on the drive shaft are not damaged.

- Install plug 999 5488 in transmission.
- Clean off traces of metal adhesive from the spline joint (hub-drive shaft).

Removing Bevel Gear





22. Mark up flange
- Mark the position of the propeller shaft flange in relation to the bevel gear flange.

NOTE: Mark up only if reinstalling the bevel gear,

- Remove propeller shaft screws.
- Use counterhold 999 5561.
Tool modified for clearence as required.
- Remove shaft from bevel gear.
- Tie up the shaft to the front exhaust pipe.





23. Remove bevel gear
- Remove exhaust pipe bracket
- Remove other screws holding bevel gear.
- Lift down bevel gear


Removing Transmission





24. Lower engine and transmission
- Lower the lifting hook until the distance between the lifting beam and the spark plug cover is approximately 320 mm (12.298 inch).

NOTE: Make sure cables and hoses are not pinched or stretched and that the engine dipstick is free from the fan.





25. Install transmission fixture
- Install fixture 999 5972 and transmission fixture 999 5463 on the mobile jack.
- Install transmission fixture on transmission.
Use torque rod stay screws.
- At the same time locate support plate (marked 999 5463-1) on the fixture.
Install mobile jack lightly.





26. Remove torque converter and transmission screws
- Install counterhold 999 5656 onto the transmission as a sealing plug.
- Remove front lower plastic nut and fold out right fender liner.
- Remove torque converter screws (6 x).
Use socket Torx TX 50.
Rotate crankshaft using a socket wrench.
This is to access all the torque converter screws.
- Remove the screws between engine and transmission (7 x).





27. Remove transmission
- Ensure that torque converter is removed with transmission and does not slide off stator shaft.
Use hole in torque converter cover to press the torque converter down.

NOTE: Do not pry toward flange rim for the flywheel sensor.

Cleaning And Inspection





28. When replacing transmission: Remove oil pipe, flush and install pipe
- Remove oil pipe with hose from the old transmission.
- Rinse pipe and hose with automatic transmission fluid (ATF) of the Dexron 11 E/Ford Mercon type.
- Install oil pipe on the new transmission, use a new O-ring.
- Place a NEW O-ring on the quick-coupling.





29. When replacing transmission. Transfer the left engine mounting to the new transmission
- Torque to: 50 Nm (36.9 ft lb).





30. Flush oil cooler
- Use ATF oil
- Install a hose on upper oil cooler terminal.
- Place a container beneath the return hose.
- Flush oil cooler according to step 28 above.





31. Check carrier plate
- Make sure carrier plate is not damaged or cracked
- Check:
That mating surfaces between the transmission and engine are clean, and that guide bushings are intact and in position.
That the torque converter bushing in the crankshaft is intact.





32. Checking torque converter
- Ensure that torque converter cover mating surfaces are clean.
- Apply a light coating of grease to torque converter guide studs and in the holes for the guide bushings on the torque converter cover.
- Ensure that torque converter is as far into the transmission as possible.
- Check with a ruler.
The distance between the cover and retaining tabs should be approximately 14 mm (0.551 inch).





33. Check
- Check that the terminal sleeve (arrow) between the transmission and bevel gear is in position.