Transmission, Removing
Transmission, removing
Special tools:
998 5972 JACK 998 5972 Jack
999 5460 Lifting hook 999 5460 Lifting Hook
999 5462 Jimmy tool 999 5462 Jimmy Tool
999 5463 FIXTURE 999 5463 Fixture
999 5488 PLUGS 999 5488 Plugs
999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket
999 5716 Reading off tool 999 5716 Reading Off Tool
999 5972 FIXTURE 999 5972 Fixture
999 7057 Counterhold 999 7057 Counterhold
999 7076 Lever 999 7076 Lever
999 7077 Jimmy bar 999 7077 Jimmy Bar
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.
Removal
Removing engine compartment components
Remove:
- the engine stabilizer brace between the suspension turrets and the engine
- the cover on the side of the air cleaner (ACL) housing
- the fresh air intake hose
- the air cleaner (ACL) assembly, unhook the control valve from the air cleaner (ACL) housing
- the charge air pipe over the engine.
Removing the charge air pipe
Detach the charge air pipe from the charge air cooler (CAC). Carefully heat around the pipe at the charge air cooler (CAC). Use a hot air gun.
Work the pipe off
Removing components from the transmission
Plug the clutch cable hose using a hose clip.
Remove:
- the clutch hose from the junctions. Seal the opening to prevent intrusion of dirt. Wipe up any spillage
- the cable harness clamps
- the ground lead from the transmission and the sub-frame
- the bracket for the air cleaner (ACL) housing from the transmission.
Removing the gear selector cables from the transmission
Note! When working with the mechanical cables ensure that the cable sleeves do not crack or break.
Use jimmy bar 999 7077 Jimmy bar 999 7077 Jimmy Bar.
Remove:
- the gear selector cables from the levers
- the mechanical cables from the bracket by moving the sleeves back on the cables. Tie up the cables
- the connector for the back-up lamp switch
- the bracket with the connectors for the heated oxygen sensors (HO2S)
- the bracket for the coolant hose(s)
- the clamp for the cable harness at the rear of the engine.
Tie up the cable harness and the coolant hose(s)
Remove:
- the 3 screws for the transmission / engine
- the 2 screws for the starter motor.
Removing the coolant hose from the passenger compartment heater
Clamp the hoses with hose clips.
Place paper under the inner hose connection to collect any spilled coolant.
Turn the quick-release connector (the inner of the 2 hoses) slightly in the direction of the arrow so that the lock opens. At the same time, pull the coolant hose straight out of the coolant pipe.
Note! Tie the hose up to the engine so that it does not fall down and trap the hose connector against the firewall during installation.
Installing the lifting beam and lifting hook on the engine lifting eyelet
Position lifting beam 999 5716 Reading off tool 999 5716 Reading Off Tool directly above the engine lifting eyelets.
Connect lifting hooks 999 5460 Lifting hook 999 5460 Lifting Hook.
Left side: Tighten to light contact.
Right-hand side: Leave a clearance of 5-10 mm.
Removing the air baffle and splash guard under the engine
Remove:
- both the front wheels
- the splash guard under the engine
- the screws for the air baffle. Press in the catches holding the air baffle. Remove the air baffle.
Removing the screw for the cable duct
Unhook the cable duct from the sub-frame.
For cars with fuel powered parking heaters:
Remove the 2 screws for the heater.
Unhook the heater from the mounting. Leaving it hanging in its upper mounting.
Detach the fuel line for the heater from the holders on the sub-frame.
Removing the cross members from the body
Remove:
- the clamp for the heated oxygen sensor (HO2S) cable and the screws for the front member
- the brake pipe from the holders on the member
- the rear member
- one screw and slacken off the other.
Turn the member to the side so that the exhaust pipe is exposed.
Removing the front mounting for the exhaust pipe
Remove rubber mounting for the exhaust system from the brackets.
Removing the propeller shaft
Mark the position of the propeller shaft in relation to the bevel gear flange.
Remove the propeller shaft screws. Use counterhold 999 7057 Counterhold 999 7057 Counterhold.
Removing the mounting for the center bearing for the propeller shaft
Remove the screws for the propeller shaft bearing in the support for the center bearing.
Slacken off the screws for the support for the center bearing on one side. Remove them completely from the other side.
Press the propeller shaft CV joints together. Angle the axle so that it can be removed from the bevel gear.
Removing the screws and nuts for the engine pad, engine stabilizer brace and steering gear
Remove:
- the screw for the front engine pad
- the screws for the torque rod
- the screw and nuts for the steering gear.
Detaching the power steering line
Remove the screws and the clamps from the power steering line on the right-hand side of the sub-frame at the front and rear edges (applies to certain versions). Unhook the servo and the evaporator line from the holders on the right-hand side of the sub-frame.
Removing front suspension components (both sides)
Disconnect the ABS line from the mounting in the spring strut.
Remove:
- the screw for the drive shaft using a screwdriver in the brake disc vents
- the link from the anti-roll bar
- the nut for the ball joint / link arm. Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut.
Note! Counterhold at the ball joint pinion using a Torx TX 40 when removing the nut. This is so that the ball joint boot does not turn.
Preparations when removing transmission
Remove the 2 nuts from the fender liner and the support plate. Angle out and tie up the fender liner to the lifting beam using a retaining strap.
Note! Do not forget to protect the front fender.
Draining transmission fluid
Position a container underneath the transmission.
Re-install the plug and tighten. See the relevant specifications.
Removing the screws for the sub-frame support plates (both sides)
Remove the screws from the sub-frame support plates (both sides).
Position mobile jack 998 5972 JACK 998 5972 Jack with universal plate 999 5972 FIXTURE 999 5972 Fixture , so that the plate is in light contact under the right-hand side of the sub-frame.
Slacken off the screws for the sub-frame on the right hand side. Ensure that the nuts are still secured by at least 5 threads.
Remove the jack.
Unhook the control arm from the ball joint. Use jimmy tool 999 7076 Lever 999 7076 Lever. Install protective sleeve 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket.
Hold the sleeve in place using the nut for the ball joint.
Pull out the spring strut and remove the drive shaft from the hub. Do not damage the boot.
Hold the spring strut to one side using a retaining strap for more space when removing the drive shaft.
Keep the seal on the outer constant velocity joint housing if it falls off.
Removing the right drive shaft
Remove:
- the support bearing cap for the drive shaft
- the drive shaft by pulling it straight out of the transmission.
Removing the collision protection system over the steering gear
Note! Applies only to right-hand drive cars.
Remove the 2 screws for the collision protection system. Leave the collision protection system in place on the steering gear.
Lowering the sub-frame
Position the mobile jack lightly applied under the left side of the sub-frame.
Remove the sub-frame screws.
Note! When lowering ensure that the screws for the steering gear release from the sub-frame. Ensure that the ball joint pinion releases from the control arm.
Remove the mobile jack and let the frame hang loose.
Removing the drive shaft
Pull out the spring strut and remove the drive shaft from the hub. Hold the spring strut to one side using a retaining strap for more space when removing the transmission.
Remove the drive shaft from the transmission. Use jimmy tool 999 5462 Jimmy tool 999 5462 Jimmy Tool.
Install sealing plug 999 5488 PLUGS 999 5488 Plugs in the transmission.
Removing bevel gear
Remove the 5 screws holding the bevel gear straight out from the transmission.
Removing the rear engine mounting
Remove:
- the screw for the engine pad / steering gear
- the 3 screws. Remove the mounting and engine pad.
Hanging up the steering gear
Hang up the steering gear in a tie strap. Use the hole in the body.
Lowering the engine and the transmission
Lower the engine and transmission on the left-hand side using the hook.
Note! Check that no hoses or cables are being stretched or trapped when the engine is lowered.
Lower the engine to the lifting hook stop. This can be seen in the hole in the upper section of the hook as arrowed.
Raise the car.
Installing the fixture on the mobile jack and transmission
Install transmission fixture 999 5463 FIXTURE 999 5463 Fixture on fixture 999 5972 FIXTURE 999 5972 Fixture. Position the unit on mobile jack 998 5972 JACK 998 5972 Jack.
Align the fixture on the transmission using the 2 screws for the engine stabilizer brace. At the same time align support plate 5463-1 with the fixture and the transmission. Tighten the screws.
Apply the mobile jack lightly against the transmission.
Removing all the screws for the transmission and engine
Remove the remaining 7 screws for the transmission and engine.
Removing the transmission
Note! Ensure that the transmission is removed straight out in relation to the engine so that no damage occurs between the primary shaft for the transmission and the center of the clutch driven plate.
Lower the transmission when it is free from the clutch.
Remove the transmission.