Transmission, Removal
Removing the transmission
Special tools:
998 5972 JACK 998 5972 Jack
999 5006 LIFTING BAR 999 5006 Lifting Bar
999 5033 SUPPORT 999 5033 Support
999 5045 COMPRESSION HOOK 999 5045 Compression Hook
999 5185 HOOK 999 5185 Hook
999 5186 HOOK 999 5186 Hook
999 5259 SEPARATOR 999 5259 Separator
999 5460 Lifting hook 999 5460 Lifting Hook
999 5463 FIXTURE 999 5463 Fixture
999 5560 PULLER 999 5560 Puller
999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket
999 5563 SUPPORT 999 5563 Support
999 5681 Jimmy bar 999 5681 Jimmy Bar
999 5716 Reading off tool 999 5716 Reading Off Tool
999 5972 FIXTURE 999 5972 Fixture
Filling in Diagnostic and Check lists
Note! Before replacing the transmission, fill in.
Removing engine compartment components
Remove:
- the air cleaner housing ACL assembly with the intake pipe
- the battery
- the battery shelf.
Removing the connector and vacuum hose
Remove the connector under the panel for the radiator.
Pull the connector straight out towards the engine.
Unhook the connector from the fan shroud.
Remove the vacuum hose from the intake manifold.
Removing the screw for the torque rod / torque control arm at the engine
Disconnect the ground strip from the firewall.
Removing the transmission cable from the lever. Removing the mounting on the transmission and the oil pipe
Remove:
- the transmission cable from the lever and the screws from the bracket on the transmission
- the large connector
- the 2 nuts for the cable conduit on the transmission
- the connector at the cable conduit furthest in at the transmission
- the oil pipe from the transmission. Plug the transmission and pipe.
Separate the connector beside the large connector.
Removing the mounting screws for the transmission / starter motor
Fold the connectors, cable harness and cable conduit out of the way of the engine / transmission.
Remove:
- the 3 screws for the transmission / engine
- the 2 screws for the starter motor. One screw is located under the starter motor
- the ignition setting sender.
Installing lifting tools
Install lifting beam 999 5716 Reading off tool 999 5716 Reading Off Tool. Install lifting hooks 999 5460 Lifting hook 999 5460 Lifting Hook and 999 5185 HOOK 999 5185 Hook.
Lift the engine to relieve the load on the engine pads.
Removing both the front wheels. Removing the control arms, the tie rod, the brake pipe bracket and the screw for the drive shaft on both sides
Remove:
- the link for the anti-roll bar up at the spring strut
- the tie rod from the wheel spindle. Use puller 999 5259 SEPARATOR 999 5259 Separator
- the screw for the brake pipe bracket
- the screw for the drive shaft.
Removing the front protective cover
Remove the screws and the cover.
Removing the screws for the cable conduit and ground lead bracket
Removing under body components
Remove the carbon filter container with its hoses from the sub-frame.
Cut off the tie straps for the hoses. Hang up the container in the bodywork.
Loosen the clamp for the exhaust pipe behind the three-way catalytic converter (TWC).
Slacken off the screw for the bracket for the ground lead.
Remove the screw for the ground lead from the transmission.
Draining the transmission oil
Remove:
- the screws for the oil pipe brackets
- the two screws for the torque rod mounting support on the transmission.
Drain the transmission oil.
Note! Drain the oil only if replacing the transmission or changing the oil. Tighten the drain plug to 40 Nm.
Warning! The oil may be extremely hot.
Removing the oil pipe from the transmission
Collect the, approximately, 1/2 - 1 dl of oil that runs out when the oil pipe is detached from the transmission.
Slacken off the screw. Pull the pipe out of the transmission.
Plug the oil pipe and the transmission.
Removing the collision protection system over the steering gear (right-hand drive cars only)
See Removing the transmission Transmission, Removal.
Disconnecting the control arms from the wheel spindles
See Removing the transmission Transmission, Removal.
Removing the right drive shaft
Remove the bearing cap.
Pull out the inner section of the drive shaft. At the same time fold out the spring strut.
Caution! Take care not to damage the seal in the transmission.
Removing the screw for the front engine pad in the sub-frame
Slacken off the screw for the engine pad.
Remove the 5 mounting nuts for the steering gear in the sub-frame.
Right-hand drive cars only:
Remove the nut (A) for the collision protection system / sub-frame.
Preparations for removing the sub-frame from the car
Position mobile jack 998 5972 JACK 998 5972 Jack at light contact under the left-hand side of the sub-frame as support.
Remove the screws for the sub-frame support brackets in the body (both sides).
Unscrew the two screws between the frame and body (right side) by approximately 15 mm . Remove the screws on left-hand side.
Preparatory lowering of the sub-frame (applies only to right-hand drive cars only)
Removing the transmission Transmission, Removal.
Lowering the sub-frame
See Removing the transmission Transmission, Removal.
Mounting the steering gear on the left-hand side in the hole in the frame member flange
See Removing the transmission Transmission, Removal.
Removing the rear engine mounting from the transmission
Slacken off the clamp for the cable for the heated oxygen sensor (HO2S).
Remove the three screws for the engine mounting.
Removing the left drive shaft
Turn and fold out the spring strut. Knock the end of the drive shaft with a rubber or copper mallet. Pull the end of the drive shaft out of the hub.
Remove the drive shaft from the transmission. Use lever 999 5681 Jimmy bar 999 5681 Jimmy Bar between the transmission and the inside of the drive shaft.
Caution! Pull at the constant velocity joint, not the shaft, when removing the drive shaft. This is to help prevent excessive load on the joint axial stop. Take care not to damage drive shaft seal and boots.
Lower the car
Lowering the engine and the transmission
Lower using the lifting hook until the distance between the lifting beam and the spark plug cover is approximately 320 mm .
Note! If the engine is lowered too much, the exhaust pipe may press the steering gear down.
Note! Make sure that all cables and hoses are not pinched or stretched. Check that the engine dipstick is free from the fan.
Raise the car
Preparations for removal of the transmission
Remove:
- the contact rubber on the sub-frame
- the nut for the fender liner. Bend out the fender liner.
Drill out the four rivets in the front edge of the left fender liner.
Installing the mobile jack and fixture
Use mobile jack 998 5972 JACK 998 5972 Jack together with the fixtures 999 5972 FIXTURE 999 5972 Fixture and 999 5463 FIXTURE 999 5463 Fixture.
Install the transmission fixture on the transmission: Use the screws for the torque rod mounting.
At the same time, locate the bearing plate (marked 999 5463-1) on the fixture.
Raise the mobile jack into contact.
Removing the six screws for the torque converter
Remove the lower plastic nut. Bend out the right inner fender.
Turn the engine with a ratchet and socket. Use a Torx TX 50 socket on the torque converter screws (see the illustration).
Removing the 6 screws for the transmission / engine
Removing the transmission
Note! Lower the transmission slightly when it is being removed so that it will pass the side member.
Ensure that the torque converter is removed with the transmission and does not slide off the stator shaft. Use the hole in the torque converter cover to press the torque converter down.
Note! Do not pry toward the flange rim for the flywheel sensor.
Checking the carrier plate
Check that the carrier plate is not damaged or cracked.
Check that:
- the mating surfaces between the transmission and engine are clean. Check that the guide bushings are intact and in position
- the bushing for the torque converter in the crankshaft is fault free.