Removal and Replacement
Cable harness/oil temperature sensor, replacing
Special tools:
998 5972 JACK 998 5972 Jack
999 5460 Lifting hook 999 5460 Lifting Hook
999 5477 JOINT WEDGE 999 5477 Joint Wedge
999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket
999 5716 Reading off tool 999 5716 Reading Off Tool
999 5972 FIXTURE 999 5972 Fixture
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.
Removal
Preparations
Switch off the ignition.
Removing the air cleaner (ACL) housing
Remove the air cleaner housing ACL assembly with the intake pipe.
Remove the gearbox cable from the lever on the gearbox
Unhook the mounting with the connectors for the gearbox from the bracket for the air cleaner (ACL) housing.
Remove the tie straps from the cable harness.
Remove the mounting from the cover for the control system.
Separate the connectors. Remove the connectors from the mounting.
Removing the lever on the gear shift linkage rod
Remove:
- the lever on the gear shift linkage rod
- the screw for the gear selector sensor and cable harness.
Twist out the tab on the cable harness holder.
Installing the lifting beam and lifting hook
Install lifting beam 999 5716 Reading off tool 999 5716 Reading Off Tool directly above the engine's lifting eye. Position the lifting beam's brackets as illustrated.
Connect hook 999 5460 Lifting hook 999 5460 Lifting Hook to the lifting eye at the rear edge of the engine. Apply the hook to take the load off the engine pads.
Lifting the car
Note! Position the front lift arms so that they do not block the sub-frame's support plates.
Remove:
- the front wheels
- the splash guard under the engine
- the outer front protection on both sides
- both the screws for the front splash guard. Press in the catches at the front edge of the cover. Pull the cover backwards
Removing the screw for the right drive shaft
Remove the ABS sensor from the stub axle. Hang it up on the spring strut.
Remove the drive shaft screw. Counterhold using a screwdriver in the brake disc vents.
Removing the screws for the cable conduit and ground lead bracket on the sub-frame
Only applies to cars with parking heater:
Remove the three screws for the heater on the sub-frame.
Hang or tie up the heater on the left front wing.
Unhook the fuel line from its mountings in the sub-frame.
Removing the ball joint nuts (both sides)
Remove the nut for the lower ball joint and control arm. Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut. Counterhold with Torx TX 40 at the ball joint pinion when removing the nut. This is so that the ball joint boot does not turn.
Remove the nuts for the anti-roll bar links. Unhook the links from anti-roll bar.
Removing the bracket for the power supply cable for the heated oxygen sensor (HO2S)
Remove the screws for the bracket.
Applies only to right-hand drive cars
Remove the front cross member
Remove:
- the screws for the cross member
- the screws for the rubber mounting
- the brake pipe from its holders
Removing the collision protection system over the steering gear
Applies only to right-hand drive cars
Remove the collision protection over the steering gear.
Removing the steering gear from the sub-frame
Remove:
- the nuts and screws for the steering gear
- the screw for front engine pad and sub-frame
- the screws securing the torque rod mounting on the gearbox
Unhook the power steering fluid line from the sub-frame
Removing the screws from the sub-frame support brackets (both sides)
Position mobile jack 998 5972 JACK 998 5972 Jack with fixture 999 5972 FIXTURE 999 5972 Fixture to light contact under the sub-frame's right side.
Remove the sub-frame screws on the right-hand side. Unscrew the screws so that at least five threads remain. Remove the jack.
Ensure the stub axle is twisted for turning left. Unhook the control arm from the ball joint. Remove the drive shaft from the hub.
Install protective sleeve 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket , which is locked in place with the nut for the ball joint.
Move the spring strut slightly backwards. Take care that the control arm does not damage the drive shaft boot.
Lowering the sub-frame
Position the mobile jack lightly applied under the left side of the sub-frame. Remove the front and rear screws from the sub-frame.
Carefully lower the frame a little. Check that the screws for the steering gear release from the frame and the control arm releases from the ball joint. Lower the sub-frame completely and let it hang free.
Draining the gearbox fluid
Place a container underneath the gearbox.
Drain the oil. Measure and note the volume of oil. Then tighten the plug. Tighten to 40 Nm.
Remove the cable harness clamp on the control system cover. Disconnect the ground lead from the gearbox. Tie up the cable harness and ground lead.
Disconnect the oil cooler return line from the control system cover.
Disconnect the oil cooler pipe and hose from the gearbox. Move the pipe to one side.
Seal the hole in the gearbox with a plastic plug.
Removing the control system cover
Remove the Torx TX40 screws for the control system cover.
Clean the sealing compound from the threads. Use tap M8 x 1.25.
Remove the cover. Use gasket wedge 999 5477 JOINT WEDGE 999 5477 Joint Wedge. Carefully tap it in between the cover and transmission so that the cover's seal flange is not distorted.
Clean the gasket residue from the cover and the gearbox.
Note! Make sure that no debris enters the transmission. Clean the cover thoroughly.
Removing the cable harness
Remove:
- the connectors for the solenoid valves
- the screw for the oil temperature sensor holder. Remove the sensor from the control system
- the cable harness from the holders on the control system
Remove the cable harness.
Installation
Connecting the cable harness
Lubricate the O-rings for the cable harness grommet and the oil temperature sensor with automatic gearbox fluid.
Install:
- the cable harness. Connect the connectors to the solenoids
- the oil temperature sensor with the holder and screw. Tighten to 10 Nm
- the cable harness on the holder. Check that the cable harness is correctly positioned
Sealing the cover
Check that the mating surface for the cover is level.
Wipe the cleaned mating surfaces on the cover and gearbox. Use methylated spirit.
Note! Make sure that no dirt gets into the transmission.
Apply a bead of sealing compound, approximately 3 mm thick, to the cover. P/N 1161409-6. Apply the compound around the screw holes.
Installing the control system cover
Reinstall the control system cover on the gearbox. Tighten the screws alternately. Tighten to 12 Nm. Torx TX 40.
Stretch the cable up to the oil temperature sensor.
Install:
- the oil pipe on the gearbox with a new O-ring
- the return line to the control system cover
- the cable harness to the holder on the cover
- the ground lead on the transmission
Installing the sub-frame
Position the mobile jack 998 5972 JACK 998 5972 Jack under the left side of the sub-frame.
Press the frame up against the car body. At the same time locate the ball joint on the control arm and the steering gear screws to the frame.
Note! Use new screws. Lube the screws with oil.
Install new screws (M14) in the sub-frame. Tighten screws with 105 Nm. Install the support plate's screws at the same time.
Right-hand side
Align the drive shaft in the hub.
Remove the protective cover from the ball joint. Locate the ball joint pinion in the control arm. Position the mobile jack under the right side of the sub-frame. Press up the sub-frame and install the new screws in the same way as on the left-hand side. Remove the jack.
Finally tighten the four screws for the sub-frame to 120°.
Tighten the screws for the support plate. Tighten to 50 Nm.
Installing components in the steering gear and sub-frame
Install:
- new lock nuts and screws on the steering gear. Tighten to 50 Nm
- the screw for the front engine pad. Tighten to 50 Nm
- new screws for the torque rod mounting. Tighten to 35 Nm and angle tighten + 40°
Press the power steering line into the holders on the sub-frame.
Installing the nuts securing the ball joint to the control arm and the anti-roll bar to the link rods
Install the nuts for the ball joint and control arm: Counterhold with a Torx spanner so that the boot does not rotate. Tighten to 80 Nm
Install the anti-roll bar and link rods: Use new nuts. Tighten to 50 Nm.
Installing the collision protection system over the steering gear
Applies only to right-hand drive cars
Install the collision protection on the steering gear. See Installing the gearbox, B5254T2, AW50/51 AWD, B5254T2, AW55-50/51SN Gearbox, Installing
Installing the bracket for the heated oxygen sensor (HO2S)
Applies only to right-hand drive cars
Install the cross member.
Ensure that the brake pipe is pressed into place in its holder.
Tighten the member. Tighten to 25 Nm
Installing the screw for the drive shaft
Use a new screw. Tighten to 50 Nm
Clean the ABS sensor seat. Install the sensor on the stub axle. Tighten to 10 Nm
Installing components on the sub-frame
Install:
- the screw for the cable conduit
- the holder for the ground lead
Applies only to cars with parking heaters
Install the heater on the sub-frame.
Install the fuel line for the heater in the holders on the sub-frame.
Installing the splash guard under the engine
Install:
- the front splash guard
- the outer front splash guards
- the front wheels. See Installing wheels Service and Repair
Removing lifting beams and the lifting hook
Twist in the tab on the cable harness holder.
Install the screw for the gear-shift position sensor and holder. Tighten to 25 Nm
Install the lever on the gear shift linkage rod. Tighten the nut. Tighten to 16 Nm
Installing the connectors and the cable harness
Hook the connectors into place on the mounting. Connect the connectors
Install:
- the tie straps around the cable harness. Secure the cable harness in the cover for the control system
- the mounting for the cable harness on the bracket for the air cleaner (ACL)
- the gear selector cable and bracket. Tighten to 25 Nm. Connect the cable to the lever
Installing the air cleaner (ACL) housing
Install the air cleaner (ACL) housing, including all hoses and electrical terminals.
Fill up with new oil, part number - 1161540-8 in the amount as noted before, see Draining the gearbox fluid
AW55-50/51 Top up and check the oil level. See, Oil level, checking, B5254T2, AW50/51 AWD, B5254T2, AW55-50/51SN Checking Oil Level
TF-80SC Top up and check the oil level. See,
Note! AW55-50/51 After replacing the transmission oil, the "Transmission oil change" counter must be reset. See, Transmission fluid, replacing Transmission Fluid, Replacing
Note! TF-80SC After replacing the transmission oil, the "Transmission oil change" counter must be reset. See,
Diagnostic trouble codes (DTCs)
Check any diagnostic trouble codes (DTCs).