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Automatic transmission assembly

Automatic transmission assembly

To remove


1. Place covers over the wings to keep the paintwork clean and protect it from damage.

2. Remove the upper engine cover.


3. Remove the battery cover.


4. Remove the battery with coolant pipe, bonnet switch and fuse box.


5. Unplug the control module connector and remove the battery tray. Unplug the connector under the control module.


6. Remove the ventilation hose from the transmission.


7. Remove the gear cable from the selector lever arm. The selector lever must be in position N.

8. Remove the cable from the cable retainer by pulling back the locking sleeve.

9. Remove the ground cable from the transmission casing.

10. Remove the upper bolts of the transmission casing. For simpler dismantling, use 87 92 723 Access tool, bolt in joint between automatic transmission and engine .


11. Lift off the expansion tank from its holder and fit 83 96 178 Kit, lifting eyes B207 onto the engine.


12. Place 83 94 850 Lifting beam and 83 95 287 Holder on the engine. Remove the oil dipstick and take the weight off the engine and transmission. Note the location of the hooks in the illustration.

13. Undo the upper bumper shell mountings.


14. Suspend two 83 95 212 Strap in place above the radiator core so they are accessible from below.

15. Raise the car.

16. Remove the front wheels.

17. Remove the lower front cover.

18. Secure the radiator core with the straps.


19. Remove the radiator brackets from the subframe.


20. Cut the exhaust pipe 87 mm from the front end of the silencer and remove the pipe from the flange. Use 83 95 667 Pipe cutter/exhaust system .


21. Remove the engine torque rod from the subframe.


22. Remove the bolt and nut holding the suspension arm to the steering swivel member on both sides.


23. Detach the anti-roll bar from the link arm.

24. Unplug the connector and detach the cable clip of the headlamp angle sensor (option)

25. Remove the steering gear from the subframe. Keep the nuts and washers safe. Leave the steering gear hanging.


26. Remove the clamps holding the power steering pipe from the subframe.


27. Remove the front part of the wing liner and bend it out of the way.

28. Position a trolley lift with jig underneath.


29. Remove the subframe bolts and the rear brackets.


30. Lower the subframe slightly.

31. Pull out the steering arm ball joints from the steering swivel members.

32. Remove the anti-roll bar from the subframe, protect the steering gear boot. Fit bolts loosely in the link arms so the anti-roll bar is kept hanging in place.

33. Lower the subframe.

34. Remove the torque rod bracket. Undo the bolt for the torque rod for easier fitting.


35. Unplug the starter motor electric connections and remove the starter motor.


36. Undo the 6 bolts holding the torque converter to the driver plate. Turn the plate using an open-end spanner on the pulley centre bolt. Turn clockwise.


37. Undo the plug and press the torque converter towards the transmission and fit 87 92 574 Holder for holding the torque converter in place while removing the transmission.


38. Place a receptacle under the car and drain the transmission fluid. Refit the oil plug with a new seal.

Tightening torque 45 Nm (33 lbf ft)

39. Detach the transmission oil cooling hoses and plug the holes and hoses with 82 92 955 Plugs, spare part kit .


40. Remove the bolts in the charge air pipe bracket and move away the pipe.


41. Remove the lower transmission bolts. Leave one bolt in place loose.


42. Disconnect the ground lead.


43. Detach the ABS cable from the clip and undo the left drive shaft using 87 92 616 Removal tool, drive shafts .

44. Suspend the shaft by means of a cable tie.

45. Lower the car, mark the location of the bolts on the left engine mounting with a marker pen to ensure correct refitting and then remove the bracket from the mounting.


46. Lower the power train with the lifting beam to facilitate removal of the transmission.

47. Undo the clip securing the power steering hose.


48. Raise the car and move aside the power steering cooling coil. Hang it up with 83 95 212 Strap .

49. Raise the car. Fit 87 92 608 Holder for single-column lift onto a column jack. Adjust and tighten the tool in the transmission as illustrated. Use a bolt with 8.8 grade that is approx. 20 mm longer than the removed bolt as well as a bolt (8.8 grade) with nut on the rear lifting eye.



50. Remove the remaining bolts securing the transmission to the engine.


51. Remove the last bolt, pull out the transmission and lower it.

Important

The jack can tip over. Be careful.



52. 51. Lift the transmission down from the column jack with an engine lift and 87 92 442 Lifting cable while undoing the lifting tool from the transmission.

53. Plug the holes for the drive shafts if the transmission is to undergo transport.


To fit

When fitting a new transmission, transfer the holder for the torque converter from the new transmission to the old one.


1. Turn the torque converter so that the bolt holes line up with the holes in the driver plate.

Fit 87 92 574 Holder for holding the torque converter in place while fitting.


2. Make sure the two guide sleeves are on the engine and apply anti-corrosion agent to the sleeves.

Fit new drive shaft seals, lubricate them before fitting. Use 87 92 657 Fitting drift, drive shaft seals .

3. Lift up the transmission with an engine lift and 87 92 442 Lifting cable .

4. Fit 87 92 608 Holder for single-column lift onto a column jack.

5. Secure the tool to the transmission as for removal.

Important

The jack can tip over. Be careful.



6. Fit 83 95 162 Protective collar, drive shafts in the right shaft seal in the transmission. This is done to protect the seal while the transmission is being fitted. Lubricate the seal.


7. Place the transmission in position.

Important

Slide in the gearbox until approx. 20 mm are remaining and remove the tool 83 95 162.


8. Push in the transmission until it is against the mating face. Tighten the bolts between the engine and the transmission that are accessible from below.

Tightening torque 70 Nm (52 lbf ft)


9. Remove the lifting tool from the transmission and move away the jack. Fit the bolt into the transmission.

Tightening torque 22 Nm (16 lbf ft)

10. Undo the strap and position the power steering cooling coil in place. Make sure it is fitted on the correct side of the rubber seal.


11. Lower the car and fit the mounting for the engine bracket onto the transmission. Lift up the unit and fit the bolts for the engine bracket as marked earlier.

Tightening torque 93 Nm (69 lbf ft)


12. Remove the lifting beam and undo the lifting eyes. Fit the expansion tank in its holder.

13. Fit the remaining upper bolts in the transmission. Use 87 92 723 Access tool, bolt in joint .

Tightening torque 70 Nm (52 lbf ft)


14. Fit 83 95 162 Protective collar, drive shafts into the sealing ring. Lubricate the sealing ring.


15. Make sure that the drive shaft is clean and then align it with the tool.

Important

Slide in the gearbox until approx. 20 mm are remaining and remove the tool 83 95 162.


16. Push in the rest of the shaft until the circlip clicks in.

17. Attach the ABS cable to the clip.

18. Raise the car and remove 87 92 574 Holder keeping the torque converter in place. Press the torque converter against the driver plate. Fit the plug.

19. Apply 74 96 268 Thread locking adhesive to the bolts holding the torque converter to the driver plate. Note. Use the original bolts and washers. Using longer bolts will damage the torque converter.


20. Fit the 6 bolts without tightening them.

21. Rotate the engine clockwise with the pulley and tighten the bolts once they are all in place.

Tightening torque 30 Nm (22 lbf ft)

22. Fit the starter motor with electrical connections.

Tightening torque 47 Nm (35 lbf ft)


23. Fit the charge air pipe bracket.

Tightening torque 20 Nm (15 lbf ft)


24. Change oil cooler hose seals if the transmission is to be refitted. Use 83 90 270 Sliding hammer , 87 92 319 Adapter, 3/8" - M10 and 87 92 756 Oil pipe puller .

Important

Ensure that the surfaces in the gearbox gasket opening are not damaged.



25. Fit new seals lubricated with Vaseline on the oil cooler hoses. Use 87 92 814 Fitting tool, oil pipe seal .

26. Lubricate the pipes with Vaseline, none-acidic and attach the oil cooler hoses. The pipes press holes into the seals during fitting.


27. Connect the ground cable to the transmission.

Tightening torque 10 Nm (7 lbf ft)


28. Fit the bracket for the torque arm on the transmission.

Tightening torque 93 Nm (69 lbf ft)

29. Place the frame on the trolley lift with the jig.

30. Lift the frame. Make sure the power steering pipe is positioned correctly. Position the suspension arm ball joints in the steering swivel member. Fit the anti-roll bar to the subframe. The opening of the rubber bushes must be facing front.

Tightening torque 64 Nm (47 lbf ft)

31. Lift in place the subframe. Steer the guide pins in the fixture to the holes in the body.

32. Fit the subframe bolts and rear brackets. Lift the subframe against the body so that the bushes do not rotate when the bolts are tightened. Remove the trolley lift.¨

Tightening torque, subframe: 75 Nm +135°(55 lbf ft + 135°)

Tightening torque, rear bracket bolts: 90 Nm +45° (60 lbf ft + 45°)



33. Fit the steering gear with bolts, washers and nuts.

Tightening torque 50 Nm +60°(37 lbf ft + 60°)

34. Fit the engine torque rod to the subframe.

Tightening torque 70 +90° Nm (52 lbf ft +90°)

35. Fit the suspension arms to the steering swivel members.

Important

Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.


Tightening torque 50 Nm (38 lbf ft)


36. Fit the radiator brackets to the subframe. Make sure the upper radiator core mountings are located correctly in the upper brackets.

Tightening torque 47 Nm (35 lbf ft)

37. Remove the straps.

38. Set up 83 96 152 Engine centring tool kit and check that the engine is located correctly in relation to the subframe. Remove the centring tool.


39. Fit the power steering pipe to the subframe. Insert all the bolts first and then tighten them.


40. Fit a joint clamp on the front pipe and fit the front exhaust pipe to the catalytic converter. Use a new gasket and new nuts.

Tightening torque: 25 Nm (18 lbf ft)


41. Adjust the joint clamp so that the pipe ends are in the middle. Tighten the joint clamp nuts.

Tightening torque: 40 Nm (30 lbf ft)

42. Fit the front wing liner section on both sides of the car.


43. Fit the wheels. See Wheels .

Tightening torque 110 Nm (81 lbf ft)

44. Fit the lower front cover.

45. Lower the car to the floor.

46. Fit the upper bumper shell mountings.

47. Fasten the ground cable to the left engine bracket.


48. Fasten the cable to the cable retainer by pulling back the locking sleeve.

49. Fit the gear cable to the selector lever arm.

50. Carry out Checking and adjustment, selector lever cable .

51. Fit the transmission ventilation hose. Lubricate the hose sparingly with Vaseline.

52. Plug in the connectors under the control module, fit the battery tray and plug in the control module connector.


53. Fit the bonnet switch, cooling pipe, main fuse box and battery.


54. Fit and connect the battery cables.

55. Fit the battery cover.


56. Fit the upper engine cover. Put back the engine dipstick.


57. Fill 3 litres of transmission fluid through the dipstick hole using 87 92 822 Oil filler funnel with hose. Put back the dipstick. Check the fluid level, see Checking the transmission fluid level .

58. Remove the wing covers.

59. Carry out Measures after disconnecting the battery .

60. Test drive the car with varying load and engine speed and read off any diagnostic trouble codes. Also check the position of the steering wheel when driving directly forward on a flat road. Adjust if necessary. Carry out Adaptation, resetting .