Transmission, Removal
Removing the transmission
Special tools:
998 5972 JACK 998 5972 Jack
999 5259 SEPARATOR 999 5259 Separator
999 5460 Lifting hook 999 5460 Lifting Hook
999 5463 FIXTURE 999 5463 Fixture
999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket
999 5716 Reading off tool 999 5716 Reading Off Tool
999 5724 Cover 999 5724 Cover
999 5725 Fixture 999 5725 Fixture
999 5736 Wrenches 999 5736 Wrenches
999 5972 FIXTURE 999 5972 Fixture
999 7018 Lifting lug 999 7018 Lifting Lug
Disconnect the battery lead
See Battery, disconnecting Battery Disconnecting
Remove the engine compartment components
Remove:
- the air cleaner (ACL) housing assembly. See Brake pipe master cylinder / ABS unit, replacing Brake Pipe Master Cylinder / ABS Unit, Replacing
- the cross member.
Install the lifting hook
Slacken off the screw for the ground strip.
Install lifting hook 999 7018 Lifting lug 999 7018 Lifting Lug.
Remove the hose for the clutch cylinder
Block the hose between the brake fluid reservoir and clutch slave cylinder. Use hose pliers.
Remove the retaining clip from the clutch pipe junction.
Remove the pipe from the junction and from the clip in the side member.
Note! Seal the openings against contamination. Wipe up any spilled brake fluid.
Disconnect the connectors. Disconnect the transmission cables
Remove:
- the connector for the ABS control module
- the connector for the back-up (reversing) light switch
- the lock for the transmission cables from the levers
- the transmission cables from their mountings on the transmission (pull the clips upwards).
Secure the cables to the ABS brake pipes.
Remove the gear selector housing
Remove the 4 screws for the gear selector housing.
Carefully tap the control housing using a plastic hammer.
Lift and turn the control housing straight up from the transmission.
Install protective cover 999 5724 Cover 999 5724 Cover over the control housing.
Remove the screw and the tie strap for the cable harness and the ground lead
Remove
- the screw in the bracket for the cable harness
- the tie strap at the cable harness
- the ground lead screw (under the starter motor).
Tie the cable harness to the intake manifold.
Remove the screw and the clamp for the servo oil pipe
Remove the screw and the clamp for the servo oil pipe.
Remove the screws for the transmission / engine
Remove:
- the 3 screws for the transmission. Remove the 2 screws for the starter motor
- the screw for the ignition setting sensor. Pull the sensor straight up.
Install the lifting beam and the lifting hook on the engine lifting lugs
See.
Remove the suspension components
Raise the car
Note! Position the front lift arms so that they do not obstruct the sub-frame support plates.
Remove:
- the front wheels
- both the screws for the front splash guard. Remove the cover: Press in the catches at the front edge of the cover. Pull the cover backwards
- the splash guard under the engine.
Remove the screws for the cable conduit and the ground lead bracket on the sub-frame
Remove the nut for the lower ball joint / control arm
Clean the exposed threads outside the nut.
Spray with 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 control arms and the tie rod from both sides
Remove:
- the link for the anti-roll bar up at the spring strut. Counterhold using Torx 30. The rubber boot must not be twisted
- the tie rod from the wheel spindle. Use puller 999 5259 SEPARATOR 999 5259 Separator
- the screw for the drive shaft.
Remove the screws from the sub-frame support plates (both sides)
Preparations for removal of the wheel spindle
- position fixture 998 5972 JACK 998 5972 Jack (light contact) under the right-hand side of the sub-frame
- slacken off both the sub-frame screws completely. Screw the screws back in approximately 5 turns
- lower the sub-frame so that it rests against the screws and the mobile jack.
Remove the wheel spindle from the control arm
Pry the control arm with a crowbar. At the same time, lift the wheel spindle and spring strut from the control arm.
Note! Install protective socket 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket on the wheel spindle ball joint. Do not damage the rubber bellow for the ball joint.
Press up the sub-frame on the right-hand side
Tighten the sub-frame screws to light contact. Then slacken off the screws approximately 4-5 turns.
Note! This is because the sub-frame hangs down more on one side.
Move the mobile jack to the left hand side.
Remove the drive shaft from the wheel spindle (right-hand side)
Take hold of the drive shaft. Pull it down towards the control arm so that it does not tension.
Pull the brake disc outwards. At the same time, pull on the constant velocity joint towards the transmission so that the drive shaft loosens.
Allow the drive shaft to lie on the control arm.
Remove the support bearing cap from the drive shaft
Remove the screws from the bearing cap.
Remove the drive shaft
Take hold of the inner constant velocity joint. Pull the drive shaft straight out of the transmission.
Note! Do not damage the seal.
Note! Do not under any circumstances pull the drive shaft in such a way that could cause the joints to separate. The joints do not have axial pinions.
Remove the front cross member
Remove:
- the 4 screws
- the 2 screws for the rubber mounting of the exhaust pipe
- the brake pipe from its holders
- the member.
Slacken off the center and rear cross members.
Remove the screw so that the cross member hangs free.
Remove the bracket for the heated oxygen sensor (HO2S) wiring
Remove the screws for the bracket in the sub-frame holding the heated oxygen sensor (HO2S) cable. Push the bracket to one side.
Remove the steering gear nuts and the screw from the sub-frame
Unhook the servo and the evaporator lines from the holders on the right-hand side of the sub-frame.
Also unhook the servo line from the holder on top of the sub-frame.
Preparatory work for removing the wheel spindle on the left-hand side
Note! Cars with parking heaters: Remove the nuts for engine block heater on the sub-frame. Hang the heater on the left front fender.
Position fixture 999 5972 FIXTURE 999 5972 Fixture under the sub-frame.
Remove the sub-frame screws.
Lower the sub-frame 10 cm.
Remove the wheel spindle from the control arm.
Remove the left drive shaft from the transmission
Use 2 jimmy tools 999 5736 Wrenches 999 5736 Wrenches.
Note! Do not damage the seal.
Note! Never pull the drive shaft in a way that could cause the joints to separate. The joints do not have axial pinions.
Lower the sub-frame
Hang up the steering gear from the body. Use tie straps.
Carefully lower the sub-frame. Let it hang free.
Note! Ensure that the screws for the steering gear release from the frame.
Remove the collision protection
Note! Applies only to right-hand drive cars.
Remove the screw and the nut for the collision protection system.
Note! Ensure that the collision protection system is under the steering gear.
Remove the screw for the rear engine pad
Lift the anti-roll bar mounting a few mm. Use a jimmy bar. This makes it easier to insert the tool for the screw.
Remove the rear engine mounting
The mounting is secured with four screws.
Remove the screw for the front engine pad. Remove the torque rod screws in the transmission
Lower the car
Lower the engine with the transmission
Lower the engine / transmission on the left-hand side using the hook.
Check that no hoses are trapped or stretched on the left hand side.
Lower the engine until the distance between the upper edge of the mounting bracket and the engine is approximately 350 mm .
Raise the car
Preparations for removal of the transmission
Remove:
- the contact rubber on the sub-frame
- the 3 nuts for the fender liner. Fold the fender away from the screws
- the screw and the nut for the clamp for the cable harness on the transmission
- the bracket for the connectors.
Remove the 2 outer bracket screws (at the side member)
Install the fixture on the mobile jack
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
- fixture 999 5725 Fixture 999 5725 Fixture on fixture 999 5463 FIXTURE 999 5463 Fixture. Finger-tighten the screws.
Locate the fixture against the transmission
Locate the fixture against the transmission. The cut out in the fixture should grip the transmission housing.
Install the screw through the fixture to the transmission housing. Tighten the screw. Tighten to 50 Nm .
Apply the mobile jack lightly against the transmission.
Remove the transmission
Remove all 7 screws for the transmission / engine.
Pull the transmission straight out in relation to the engine.
Note! Lower the transmission slightly when it is being removed so that it will go past the side member.
Continue pulling the transmission straight out.
Note! It is vital that the above instructions are followed when removing the transmission from the engine. Otherwise the center of the clutch driven plate may buckle.