Transmission, Removing
Transmission, removing
Special tools:
998 5972 Jack 998 5972 Jack
999 5185 Hook 999 5185 Hook
999 5460 Lifting Hook 999 5460 Lifting Hook
999 5463 Fixture 999 5463 Fixture
999 5562 Protective Socket 999 5562 Protective Socket
999 5681 Jimmy Bar 999 5681 Jimmy Bar
999 5716 Reading Off Tool 999 5716 Reading Off Tool
999 5972 Fixture 999 5972 Fixture
999 7070 Mounting 999 7070 Mounting
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.
Note! Before replacing the transmission, fill in: Diagnostics/check list, B8444S, TF-80SC AWD, B6324S, TF-80SC, B6324S, TF-80SC AWD Diagnostics Check List and enclose in the returns box.
Removal
Disconnecting the battery lead
Disconnect the battery lead. See: Battery, disconnecting Battery Disconnecting.
Removing engine compartment components
Remove:
- the engine stabilizer brace between the suspension turrets and the engine
- the air cleaner (ACL) housing assembly with the intake pipe.
Unhook the turbocharger (TC) control valve from the air cleaner (ACL) housing.
Pull the air cleaner (ACL) housing out of its mountings.
Removing components from the transmission
Remove:
- the gear selector cable. Use jimmy tool 999 7077 Jimmy bar 999 7077 Jimmy Bar to detach the ball joint for the cable from the lever
- the cable mounting from the transmission
- the oil line from the transmission. Plug the line and the connection on the transmission cover
- unhook the mounting with the connector for the transmission from the bracket. Separate all the connectors.
Removing the mounting screws from the transmission
Remove the bracket with the connectors for the heated oxygen sensors (HO2S) and the clamp for the cable harness from the transmission.
Remove:
- the screws for the clamp securing the cable harness at the rear edge of the engine
- the nut for the bracket for the cable harness and the engine coolant hose
- the 3 screws for the transmission and engine and the 2 screws for the starter motor. Tie up the cable harness.
Removing the coolant hose from the passenger compartment heater
Clamp the hoses with hose clips.
Place some 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 between the firewall during installation.
Installing the lifting beams and lifting hooks on the engine lifting lugs
Note! The front lifting beam must be equipped with fixture kit 999 7070 Mounting 999 7070 Mounting as illustrated.
Position lifting beam 999 5716 Reading off tool 999 5716 Reading Off Tool on the wheel arch and directly above the engine lifting eyelets on the left and right-hand sides.
Connect the lifting hooks 999 5460 Lifting hook 999 5460 Lifting Hook on the engine lifting lugs.
On the right-hand side of the engine, the hook must have a clearance of 10 mm. Also use lifting lug 999 5185 HOOK 999 5185 Hook on the left-hand side of the engine. Tighten to light contact on the left hand side.
Raise the car
Removing both the front wheels
Remove:
- the front splash guard. See Sub-frame front, replacing Service and Repair
- the splash guard under the engine.
Removing components from the sub-frame
Remove 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.
Turn the member to the side so that the exhaust pipe is exposed.
Removing the screws and nuts for the engine pad, engine stabilizer brace and steering gear
Remove:
- the screw for the engine pad/steering gear
- the screw for the front engine pad
- the screws for the engine stabilizer brace.
Measuring the position of the tie rod in the steering gear
Set the front wheels to the straight ahead position.
Lock the steering wheel. On one side, measure the length of the tie rod in relation to the steering gear housing.
Note the measurement.
Disconnecting the steering gear
Remove the screw for the joint between the steering gear and the steering shaft.
Press up the joint from the steering gear.
Removing front suspension components (both sides)
Remove:
- the soundproofing over the drive shaft (applies to certain versions)
- the screw for the drive shaft. Counterhold using a screwdriver in the brake disc vents. Tap in the end of the drive shaft approximately 20 mm into the wheel hub
- the link from the anti-roll bar. Counterhold using a Torx wrench in the ball joint pinion to prevent the boot from turning. (Applies to the left-hand side only.)
- the nut for the ball joint/link arm. Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut.
Disconnecting the ball joint pinion from the control arm (both sides)
Use tool 999 7062 Separator 999 7062 Separator. Install cap nut 999 7062 Separator 999 7062 Separator for the ball joint pinion. Tighten the nut to the control arm. Then slacken off 1 to 2 turns so that there is clearance between the cap nut and the control arm.
Position puller 999 7062 Separator 999 7062 Separator on the control arm and detach the ball joint from the control arm.
Remove the tools.
Removing fender liner components (both sides)
Slacken off the 2 nuts for the fender liner and the support plate on both sides so that the fender liner can be folded out.
Removing the screws for the sub-frame support plates (both sides)
Remove the screws for the sub-frame support plates in the body (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. Install protective sleeve 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket. Hold the sleeve in place using the nut for the ball joint.
Work out the spring strut. Detach the drive shaft from the wheel 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.
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! Only applies 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
Note! Applies only to right-hand drive cars.
Position the mobile jack lightly applied under the left side of the sub-frame. Remove the sub-frame screws.
Note! Ensure the following when lowering the sub-frame:
- that the brake pipe does not catch in the bracket for the exhaust pipe mounting
- that the ball joint pinion releases from the control arm.
Remove the mobile jack and let the frame hang loose.
Removing the drive shaft from the wheel hub
Work out the spring strut. Detach the drive shaft from the wheel hub. Hold the spring strut to one side using a retaining strap to obtain more space when removing the transmission.
Removing the drive shaft from the transmission
Remove the drive shaft from the transmission. Use jimmy bar 999 5681 Jimmy bar 999 5681 Jimmy Bar.
Removing bevel gear
Remove the angle gear screws, 5. Pull the angle gear straight out from the gearbox.
Hang the bevel gear from, e.g., an oil pipe for the turbocharger or similar.
Removing the rear engine mounting
Remove:
- the 3 x screws
- the mounting and the engine pad.
Removing the screws from the torque converter
Remove the 6 screws for the torque converter. Turn the engine with a ratchet and socket. Fold out the right-hand fender liner so that the crankshaft nut can be accessed.
Use a Torx TX50 socket on the torque converter screws.
Removing the oil pipe from the transmission
Position a container under the pipe terminal.
Remove:
- the 2 screws holding the pipe. Disconnect the pipe from the transmission. Install sealing plugs in the pipe and transmission. Carefully fold the hose out of the way
- the ground lead from the transmission.
Lowering the engine and the transmission
Lower the engine and transmission on the left-hand side. Use the hook.
Check that no hoses or cables are being stretched or trapped when the engine is lowered.
Lower the engine so that 90-100 mm of the free threads on the lifting hook can be seen.
Raise the car.
Installing the fixture on the mobile jack and transmission
Raise the car.
Install fixture 999 5463 FIXTURE 999 5463 Fixture on fixture 999 5972 FIXTURE 999 5972 Fixture. Use the fixture and plate together with mobile jack 998 5972 JACK 998 5972 Jack. Align support plate 999 5463-2 against the fixture and the transmission.
Note! The support plate is installed on the inside of the fixture mounting lug (see the illustration). Tighten the fixture with the two torque rod 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
Ensure that the transmission is taken straight out in relation to the engine.
Ensure that the torque converter is removed with the transmission and does not slide off the stator shaft.
Press a screwdriver through one of the screw holes in the carrier plate.
Note! Do not pry toward the carrier plate rim for the flywheel sensor.
Note! Lower the transmission slightly when it is being removed so that it will pass the side member.
Remove the transmission.