Gearbox/Torque Converter, Installation
Gearbox/torque converter, installation
Special tools:
999 5006 LIFTING BAR 999 5006 Lifting Bar
999 5033 SUPPORT 999 5033 Support
999 5045 COMPRESSION HOOK 999 5045 Compression Hook
999 5186 HOOK 999 5186 Hook
999 5460 Lifting hook 999 5460 Lifting Hook
999 5461 COUNTERHOLD 999 5461 Counterhold
999 5462 Jimmy tool 999 5462 Jimmy Tool
999 5463 FIXTURE 999 5463 Fixture
999 5488 PLUGS 999 5488 Plugs
999 5534 LIFTING FORK 999 5534 Lifting Fork
999 5540 COUNTERHOLD 999 5540 Counterhold
999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket
999 5563 SUPPORT 999 5563 Support
999 5972 FIXTURE 999 5972 Fixture
998 5972 JACK 998 5972 Jack
951 0030 DIAGNOSTIC KEY 951 0030 Diagnostic Key
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
115 8147 TORQUE SOCKET 1/2" 19 MM 115 8147 Torque Socket 1/2" 19 mm
Installation
Installing the transmission
Install the transmission
Use the mobile jack and gearbox fixture to adjust the height and angle. Locate the gearbox on the engine.
Fit the 7 screws. Tighten crosswise by hand. Then tighten crosswise. Torque: 50 Nm .
Note! When tightening the screws, check carefully that the guide bushings locate correctly in their guide holes. Check that the torque converter cover is in contact with the engine before tightening.
Remove the fixture and the mobile jack from the gearbox.
Installing the torque converter screws
Note! Use new screws, Torx TX50.
Align the torque converter with the carrier plate by turning the engine with the crankshaft pulley nut and turning the torque converter (accessible through the hole in the cover.)
Install all 6 screws by hand. Tighten so that the screw heads rest against the carrier plate. Now tighten with 35 Nm . Socket Torx TX 50 (early models TX40 to be changed to TX50).
Note! Remove the socket wrench from the crankshaft.
Raise the engine and transmission
Unscrew the lifting hook 999 5460 Lifting hook 999 5460 Lifting Hook to the previously noted measurement between lifting beam and spark plug cap. See item Removing Transmission, Removal.
Ensure that the dip stick pipe is free of the fan and that that no hoses or cables are crimped.
Installing the rear engine mounting on the gearbox
Install the mounting on the gearbox (3 screws). Tighten the two rear screws. Torque: 50 Nm . Remove the front screw.
Install the cover. Use the screw for the mounting.
Press up the cover against the mounting. Tighten the screw. Torque: 50 Nm .
Installing the engine pad
Align the engine pad's guide pin in the cover. Use a new nut. Fit the nut by hand.
Install the screw for the steering gear engine pad
Do not tighten the screw.
Remove the support hook 999 5045 COMPRESSION HOOK 999 5045 Compression Hook.
Install:
- Heated oxygen sensor cable with clamps in the cover
- Connector and cable to the speed sensor.
- Earth lead on the gearbox.
Right-hand drive cars only
Remove the tape from the drive shaft and let the shaft rest on the oil pipe.
Raise the frame to approx. 100 mm from the body.
Align the steering gear on the right-hand side and the collision protection system on the sub-frame. Install the screws for the anti-roll bar's left-hand bearing with the cap and tighten both bearing caps.
Torque: 50 Nm .
Installing the sub-frame
Note! Use new screws (4 x M14). Lubricate the screw threads. Make sure that the screws for the steering gear locate in the frame.
Begin on the left-hand side. Raise the sub-frame with the mobile jack.
Install the screws for the frame and support bracket. First tighten the screws with 105 Nm + 120° , then the screws to the frame's bracket with 50 Nm . Use protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor. Move the jack to the right-hand side repeat the procedure.
Remove:
- Lifting hook, lifting bar; and fender edge support.
- The lifting fork from the engine.
Tighten nut for the rear engine pad.
Torque: 50 Nm .
Install:
- The 5 nuts for the steering gear. Use the new nuts. Torque: 50 Nm.
- The nut to the collision protection system/sub-frame (A). (Only right-hand drive vehicles) Torque: 50 Nm
- The screw for the front engine mounting - sub-frame.
Tighten the screws for the front and rear engine pads. Torque: 50 Nm.
Install:
- Torque stay mounting's bracket on the gearbox.
Note! Use new screws.
Torque: Late design M10, 35 Nm + 40° . Early design M8, 18 Nm + 90° . Use protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
- The screws for the oil pipe bracket. Torque: 25 Nm .
Tighten the clamp for the exhaust pipe.
Jiggle the pipes during tightening.
Installing the right drive shaft
Note! Ensure that the seal ring in the gearbox and the boot on the drive shaft are not damaged.
Install the bearing cap. Torque: 25 Nm .
Installing the collision protection system over the steering gear (right-hand drive cars only)
(2 screws) Tighten with torque: 80 Nm .
Installing the left drive shaft
Ensure that the ABS sensor pulse wheel on the drive shaft is free of dirt.
Press in the drive shaft firmly so that the snap ring engages in its groove in the [1][2]differential gear. Check by pulling carefully on the drive shaft constant velocity joint.
Note! Ensure that the seal ring in the gearbox and the boot on the drive shaft are not damaged.
Apply metallic adhesive 1161370-0 on the drive shaft splines for the hub as illustrated.
Fold out and turn the spring strut and locate the drive shaft in the hub.
Use holder 999 5563 SUPPORT 999 5563 Support to press the control arm down.
Fit the drive shaft nut manually.
Early design (M20): Use a new oiled nut.
Late design (M22): The old nut can be used again. Oil the nut.
Remove the holder.
Note! Take care not to damage the drive shaft boot.
Fit to both sides:
- Control arm/ball joint to wheel spindle. Remove the sleeve 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket from the ball joint. Make sure that the ball joint pin's groove fits to the screw hole in the wheel spindle. Use new lock nuts for the screws. Torque: 50 Nm .
- The linkage to the anti-roll bar. Use new lock nuts. Torque: 50 Nm .
Tightening, left drive shaft nuts
Use counterhold 999 5461 COUNTERHOLD 999 5461 Counterhold (4 wheel studs) or 999 5540 COUNTERHOLD 999 5540 Counterhold (5 wheel studs) and protector 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor. Tighten with 120 Nm + 60°.
Remove the counterhold.
Lock nut, early design (M20): Knock down the nut's locking flange in the groove on the drive shaft.
Locking nut, late design (M22): The nut is self-locking.
Install:
- The bracket for the brake line /ABS cable (both sides)
- the ABS sensor in the stub axle. Clean the sensor with a soft brush.
Note! Ensure that the sensor seat is absolutely clean.
Tighten the sensor. Torque 10 Nm
- The plastic nuts (both sides) and Torx screws for the wheel arch liner (left-hand side, early design).
Install:
- The cable conduit on the sub-frame.
- The carbon filter container. Clamp the hoses to the sub-frame with tie straps. Hook the hoses into place in the sub-frame
- Cover under the engine (Early design)
Install:
- The front cover. Press it into position at the front. Press it forward and upward at the rear so that cover guide is seated in its slot. Install the screws
- Wheels. Lubricate the hub's guide for the rims with rust inhibitor 1161030-0. Tighten the screws by hand. Then tighten crosswise. Torque: 110 Nm .
Note! Also see Tightening the wheel studs Service and Repair.
Install the screws between the gearbox-engine and gearbox-starter motor.
Note! Radiator hose bracket (Early design)
Gearbox-motor (3), torque: 50 Nm
Gearbox-starter motor (2), torque: 40 Nm
Install:
- Cable conduit on the gearbox (Late design)
- Heated oxygen sensor connector on the bracket (Late design)
- Dipstick pipe with new O-ring. Torque: 25 Nm .
Install:
- Clamp/clamps for cable harness/earth cable
- Connector to the gearbox (Note the seal)
- Oil cooler hoses
- Air vent hose from the gearbox to the clamp/holder (early design).
- The hoses to the regulator valve. (Cars with EGR valve).
Adjust the gear cable and install on the gearbox.
Installation, cont.
Install:
- The ground strip in the bulkhead
- The screw and the nut for the torque control arm / torque rod.
Note! Use new screw and locknut.
Part number locknut:
- M8 (on early designs) 948 645-7
- M10 (on late designs) 971 098-9
Note! On later version the locknut is standard.
Tighten to:
- M8 18 Nm +120°
- M10 35 Nm +90°.
Only cars with turbocharged engines, early design:
Install:
- Hose to the engine's oil cooler
- Inlet manifold to the throttle housing
- The intake manifold to the turbocharger (TC)
- The hose to the charge air pipe over the engine
- Cover over the control bobbin
Only cars with turbocharged engines, late design:
Install:
- Hose to the engine's oil cooler.
- Inlet manifold to the throttle housing.
Remove the strap holding the pipe to the intercooler.
Install:
- The pipe from the turbocharger to the intercooler. Tighten the pipe bracket on the torque rod's stay. Torque: 25 Nm
- Throttle cable to the control bobbin and circlip in the cable adjuster
- Cover over the control bobbin
- The intake manifold to the turbocharger.
Install:
- The expansion tank
- The battery shelf
- The air cleaner (ACL) housing with the intake manifold and connections
- The timer valve to the air cleaner (ACL) housing (turbocharged engines only)
- The battery.
Reset the steering position.
Finishing
Checking the transmission fluid level
See Checking oil level Checking Oil Level.
Note! Only ATF oil that conforms to the requirements for both Dexron IIE and Ford Mercon may be used.
Note! When the fluid and transmission are cold and the engine is off, the right fluid level is only up a few mm on the dipstick.
Checking the diagnostic trouble codes (DTCs)
Check and erase any diagnostic trouble codes (DTCs).
The oil counter must always be erased if you have replaced or dismantled the gearbox. This also applies when exchanging the gearbox. See Resetting Transmission fluid change counter, AW55-50/51SN Resetting Transmission Oil Replacement Counter.
The adaptation must be erased with gearbox replacement according to Resetting the adaptation, AW55-50/51SN Resetting Adaptation.
Test driving
Test drive the vehicle with the test program selector in all three positions (E, W, S)
Checking the oil level
Check the fluid level when the transmission and fluid are warm.
The gear selector should be in P and the engine should be idling.
At room temperature (+20° C) the oil level is close to the MIN-mark on the "cold range" on the dipstick.
The "Cold range" (+40° C) is reached after approx.15 minutes idling in the workshop and the "warm range" (+80° C) after about 30 minutes driving on main roads at an air temperature above +15° C.
Also see Checking oil level Checking Oil Level.
Note! The check should be carried out at an oil temperature of +80° C.
Checking the diagnostic trouble codes (DTCs) after test driving
Check that no diagnostic trouble codes (DTCs) have been registered. Erase any diagnostic trouble codes (DTCs)
Returning the transmission (Only when replacing the entire transmission assembly)
Return the old transmission unit.
In order to accurately analyze the transmission fault, information is required about all symptoms which have caused the unit to be replaced. This information must be reported on the "Diagnosis and Check List" form which has been provided.
Check that the report is completed correctly.
Enter all fault symptoms in plain text under the heading "Customer complaints". Enter the results when test driving is complete.
Place the completed report in a plastic pocket behind the torque converter so it is not lost.
The report is divided as follows:
- White section, shall accompany the gearbox
- Yellow section, sent to the respective importer.
- Pink section, kept by the issuer.