Transmission, Installing
Transmission, installing
Special tools:
951 2050 Bevel Protractor 951 2050 Bevel Protractor
999 7057 Counterhold 999 7057 Counterhold
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 is always correct.
Installation
Note! For tightening torques, see: Tightening Torque
Installing the transmission
Before installing the transmission it is very important that the checks and cleaning have been carried out. See Transmission, preparations before installing Transmission, Preparations Before Installing.
Adjust height and angle with the mobile jack and the transmission fixture.
Locate the transmission on the engine.
Ensure that the transmission goes straight in, in relation to the engine, and that the guide sleeves and guide pin for the starter motor align in the guide holes on the transmission.
Installing and tightening the screws for the transmission
Install all 7 x M10 screws securing the transmission to the engine.
First tighten alternately and crosswise to light contact.
At the same time, check that the whole of the transmission is in contact with the engine.
Then tighten the screws crosswise.
Remove the fixture from the transmission.
Installing the torque converter screws
Note! Use new screws.
Align the torque converter against the carrier plate. Do this by turning the engine with the nut for the crankshaft pulley and turning the torque converter.
Install all 6 screws loosely. Tighten the screws. Tighten until the heads are almost in contact with the carrier plate. Tighten. Use a Torx socket TX50.
Note! Remove the socket wrench from the crankshaft.
Lifting the engine and transmission
Lift the engine to slightly above the horizontal position to provide better access to the rear engine mounting and engine pad.
Note! Check that the connection on the hose for the heater is not trapped between the engine and firewall when the engine is lifted.
Raise the car.
Installing the rear engine mounting
Install:
- the rear engine mounting on the transmission
- the 3 x M10 screws for the engine mounting. Tighten.
Installing the bevel gear
Note! Before installing the bevel gear, lubricate the spline joint between the transmission and the bevel gear using grease.
Ensure that the mating surfaces on the transmission and bevel gear are clean and not damaged.
Install the bevel gear. Use new screws. Tighten the screws alternately to light contact. Refer to: Bevel Gear
Installing the lower oil pipe on the transmission
Use a new O-ring.
Install:
- the oil pipe and dip stick pipe. Use both the screws. Tighten. See Tightening Torque
- a tie strap for the cable harness for the oil pipe
- the ground lead to the engine.
Installing the left drive shaft on the transmission and the wheel spindle
Press in the constant velocity joint housing firmly so that the snap ring engages in its groove in the transmission. Pull the constant velocity joint to check that the drive shaft is secure.
Lubricate the drive shaft splines. Use a small amount of thin oil. Locate the drive shaft in the wheel hub.
Install a new screw loosely in the drive shaft.
Installing the sub-frame on the bodywork
Note! Use new screws. Lubricate the screw threads.
Lift up the sub-frame until it is about 150 mm from the side member.
Secure the power steering pipe at the front edge of the upper side of the sub-frame. Use the rubber covered clamp. Install the screw loosely. Apply a small amount of soap solution so that it glides into the clamp easily.
Note! Ensure the following when lifting the sub-frame:
- ensure that the brake pipe passes the bracket for the exhaust pipe
- ensure that the ball joint pinion for the spring strut aligns in the control arm.
Install:
- the new screws and the support bracket at the rear edge
- the screws for the bracket loosely.
Applies only to cars with fuel driven parking heaters:
Align the washer with the mounting lug following the marking on the sub-frame.
Tighten the sub-frame screws. Tighten to light contact.
Remove the mobile jack.
Installing the right-hand drive shaft on the transmission, wheel spindle and control arm
Install the cap for the drive shaft pilot bearing. Use 2 x M8 screws. Tighten.
Lubricate the drive shaft splines. Use a small amount of thin oil. Locate the drive shaft in the wheel hub.
Install a new screw loosely in the drive shaft.
Press down the control arm. Locate the spring strut in the ball joint pinion for the spring strut in the control arm.
Position the mobile jack lightly applied under the right side of the sub-frame.
Install:
- new screws in the sub-frame.
Note! Lubricate the screw threads.
- the screws loosely at the rear edge of the support plate.
Tighten the sub-frame screws. Tighten to light contact.
Remove the mobile jack.
Install the four subframe screws together with the subframe brackets and engine heater where appropriate.
Tighten to: Tightening torque Tightening Torque. First tighten the screws on the left-hand side of the subframe followed by those on the right.
Tighten the bracket screws M10.
Installing components on the engine and sub-frame
Install the 1 x M10 screw for the front engine pad. Tighten.
Loosely install the screw for the engine pad/steering gear.
Tighten the M10 screw for the rear engine pad.
Install the mounting for the engine stabilizer brace to the transmission. Use new screws. Tighten. See Tightening Torque
Installing the collision protection system over the steering gear
Note! For tightening torques, see: Tightening Torque
Applies only to right-hand drive cars
Install the 2 screws. Tighten.
Checking the position of the tie rod in the steering gear
Check that tie rod is in the same position as when it was removed.
Assembling the lower steering shaft
Tighten the lower screw on the steering shaft joint mounting in the steering gear from the engine compartment. Use a new screw. Tighten. See: Tightening torque [1][2]Mechanical Specifications.
Installing the cross members on the body
Install:
- the M8 screws for the front member
- the brake pipe in the holders on the member
- the clamp with the heated oxygen sensor (HO2S) cable on the front cross member.
Installing front suspension components
Hint: Applies when installing front suspension components on both sides.
Install:
- a new M12 lock nut on the ball joint pinion. Counterhold the ball joint pinion while tightening so that the boot cannot turn. Tighten
- the anti-roll bar link. Use a new M10 lock nut. Counterhold the ball joint pinion while tightening so that the boot cannot turn. Tighten. See Tightening torque [1][2]Specifications. Tighten the drive shaft screw. Counterhold using a screwdriver in the brake disc vents. Tighten. See
- the soundproofing over the drive shaft (applies to certain versions).
Installing components for the fender liner
Install the support plate and the nuts on both sides.
Installing the cable duct
Install:
- the cable duct on the sub-frame
- any parking or additional heaters in the mounting in the sub-frame and the fuel line in the mountings.
Installing the front splash guard
Install:
- the splash guard under the engine
- the wheels. See Installing wheels Service and Repair.
Removing the lifting beams
Lower the car.
Remove the lifting beams and hooks from the engine.
Installing the coolant hose
Install the connector securing the engine coolant hose to the heater.
Remove the hose clips.
Installing the remaining screws for the transmission and starter motor
Install:
- the 3 x M10 screws for the transmission and engine. Tighten
- the 2 x M10 screws for the starter motor. Tighten. See Tightening torque [1][2]Specifications
- the bracket for the engine coolant hose and cable harness
- the bracket for the cable harness clamp and the mounting for the heated oxygen sensor (HO2S) connector at the rear edge of the transmission
- the clamp for the cable harness at the rear edge of the engine.
Installing the gear selector cable and oil pipe
Install:
- the ground lead and mounting on the sub-frame
- the oil pipe on the transmission
- the gear selector cable and bracket. Use 2 x M8 screws. Tighten.
Connect the cable to the lever. Connect the transmission connectors and the mounting for the air cleaner (ACL) housing bracket. Press the cable harness mounting into place on the control system cover.
Note! Check that the transmission bleed hose/valve is not trapped. There is a risk of overpressure in the transmission.
Installing the service clips
Note! The automatic transmission has one gear selector cable while the manual transmission has two cables.
Ensure that the gear selector cable is locked in position before installing the blue clip. Press the clip into place as illustrated.
Check that the clip is positioned in the groove as illustrated.
Installing engine compartment components
Install:
- the air cleaner (ACL) housing assembly with the intake manifold and connections
- hook the turbocharger (TC) control valve into place in the air cleaner (ACL)
- the upper engine stabilizer brace between the wheel arches. Use 4 x M10 screws. Tighten
- 1 x M12 screw for the engine stabilizer brace/engine mounting. Tighten
- the tie strap for the power steering return line in the mounting lug for the engine stabilizer brace on the right-hand side.
Fill with coolant. Carefully check while reaching operating temperature or test driving that the level remains the same and that there is no leakage.
Also see Transmission replacement, post-checking Transmission Replacement, Post-Checking.
Installing the battery lead
Connect the battery lead.
First read Battery, disconnecting Battery Disconnecting.
Finishing
Carry out checks after working on the transmission. See Transmission replacement, post-checking Transmission Replacement, Post-Checking.