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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. Disconnect the battery terminals and remove the battery and cooling pipe. Undo the cable clamp under the battery tray.


5. D223L: Remove the cover with vacuum tank, etc., and bend aside the cover. Press in the catch, detach the power steering fluid reservoir with bracket and move aside.

6. Disconnect the bonnet switch.

7. Remove the battery tray.


8. Disconnect the ground cable from the engine bracket and the reversing light switch connection.


9. Remove the gear cables from the gearbox by pulling the locking sleeves back.


10. Lift up the cables from the levers.

11. Fit 30 07 739 Hose pinch-off pliers to the clutch hose and undo the quick-release coupling from the clutch slave cylinder.


12. Remove the upper gearbox bolts. D223L: The bolt for the starter motor is longer than the other two.


13. Remove the coolant reservoir.

14. B207: Fit 83 96 178 Lifting eyes, B207 to the engine and 83 94 850 Lifting beam and 83 95 287 Holder . Swap the position of the lifting hooks on the holder.


15. Undo the upper bumper shell mountings.


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

17. Raise the car.

18. Remove the front wheels.

19. Remove the lower engine cover. (D223L), and the front spoiler shield. Detach the hose to the headlamp washers and unplug and remove the connector.


20. D223L: Remove the left side cover.

21. Secure the radiator core with the straps.


22. Remove the radiator brackets from the subframe.

23. Remove the front part of the exhaust pipe by cutting the pipe 87 mm from the end of the front silencer. Use 83 95 667 Pipe cutter/exhaust system .


24. Remove the engine torque rod from the subframe.


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


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

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

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


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


30. Detach the front part of the wing liner and bend it slightly out of the way.


31. Place 83 95 311 Trolley lift , 83 94 801 Parent fixture , 83 95 188 Basic fixture , 83 95 170 Adapter (4 pcs) and the front holder under the car. Position the locating pins and adjust the height of the adapters for even pressure.


32. Remove the subframe bolts and the rear brackets.


33. Lower the subframe slightly.

34. Remove the anti-roll bar from the subframe, protect the steering gear boot. Fit the link arm nuts loosely so the anti-roll bar is kept hanging in place.

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

36. Lower the subframe.

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


38. Place a receptacle under the car, remove the level plug and the drain plug. Drain the gearbox oil. Refit the drain plug.


Tightening torque 50 Nm (37 lbf ft)

39. D223L: Remove the bolts from the coolant pipe bracket and move aside.

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 using a screwdriver and undo the left-hand drive shaft using 87 92 616 Removal tool, drive shafts .

44. Suspend the shaft with a 83 95 212 Strap .

45. Lower the car, mark the positions of the bolts on the left-hand engine bracket with a marker pen for correct refitting and then remove the bolts from the mounting.


46. Lower the drive unit approx. 70 mm from the lifting beam to facilitate the removal of the gearbox. Measure the distance at the left-hand engine mounting.

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


48. Fit 87 92 608 Holder for single-column lift onto a column jack. Adjust and secure the tool in the transmission as illustrated. Use bolts of 8.8 grade that are about 20 mm longer than the bolts that were removed.


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


Important

The jack can tip over. Be careful.


50. 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.

51. Plug the holes for the drive shafts with 87 92 665 Protective plug, drive shaft hole if the gearbox is to be transported any distance.


To fit


1. If necessary, perform the procedure Bleeding the slave cylinder .

2. Lubricate the primary shaft splines, see Summary of lubricants and sealants .

3. Lubricate the guide sleeves on the engine with anti-corrosion agent.

4. 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.


Important

Always replace the shaft seals in the gearbox. Lubricate with gearbox oil.


5. Fit the gearbox with the lifting tool on the column jack.

Important

Make sure the gear cables are positioned correctly when lifting the gearbox.


Important

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


6. Push in the rest of the gearbox. Turn the crankshaft if necessary to get the gearbox in place.

7. Tighten all bolts except the top one between the engine and the gearbox.


Tightening torque, M10 bolts 40 Nm (30 lbf ft)

Tightening torque, M12 bolts 70 Nm (52 lbf ft)

8. D223L: Fit the coolant pipe bracket. All: Fit the charge air pipe bracket.


9. Remove the lifting tool from the gearbox and move away the jack.

10. Refit the gearbox bolts.

Tightening torque 24 Nm (18 lbf ft)

11. 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.


12. Lower the car. Lift in place the power train with the lifting beam until it meets the engine mounting.

13. Fit the bracket for the engine mounting according to the marks made earlier.


Tightening torque 70 Nm +45° (52 lbf ft +45°)

14. D223L: Remove the lifting beam. B207: Remove the holder, lifting beam and lifting eyes.

15. Fit the coolant reservoir.

16. Fit the upper gearbox bolts. D223L: The bolt for the starter motor is longer than the other two.


Tightening torque 70 Nm (52 lbf ft)

17. Raise the car.

18. Fit 83 95 162 Protective collar, drive shafts in the left drive shaft seal. Remove the strap. Make sure that the drive shaft is clean, lubricate it and then align it with the tool.


Important

Fit the driver in the gearbox until approx.20 mm are remaining and pull out the tool before the sealing surface of the shaft reaches the shaft seal.


19. Push in the rest of the drive shaft into the gearbox until the circlip clicks in.

20. Attach the ABS cable to the clip.

21. Fit the ground cable.

22. Remove the oil filler plug and fill with 3.0 l oil. See Summary of lubricants and sealants . Fit the level plug.

Tightening torque 45 Nm (33 lbf ft)

23. Fit the torque rod bracket.


24. Position the subframe using the fixture. Use also a 82 93 102 Extension, 500 mm, 3/8 square to guide the subframe. Lift until the anti-roll bar can be fitted to the subframe.

25. Undo the link arm nuts and fit the anti-roll bar to the subframe.

Tightening torque 18 Nm (13 lbf ft)

26. Fit the suspension arm ball joints to the steering swivel member.


Tightening torque 50 Nm (37 lbf ft)

Important

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


27. Check that the guide pins fit into the reference holes, adjust the subframe until the guide pins go in easily and fit the subframe bolts and brackets.


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

Tightening torque, rear subframe bolts: 90 Nm +45° (66 lbf ft +45°)


28. Fit the anti-roll bar link arms. Use a small open spanner.


Tightening torque 64 Nm (47 lbf ft)

29. Connect the connector and the cable clip to the headlamp angle sensor (optional).

30. Move away the trolley lift and jig.

31. Fit the torque rods to the subframe.


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

32. Fit 83 96 152 Centring tool, drive unit and check that the engine is correctly aligned on the subframe. Remove the centring gauge.


33. Fit the radiator brackets to the subframe. Remove the straps.


Tightening torque 47 Nm (35 lbf ft)

34. Fit the clamps holding the power steering pipe to the subframe.


35. Fit the steering gear to the subframe.


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

36. Fit a sleeve clamp to the front exhaust pipe and fit the front exhaust pipe to the catalytic converter. Grease the threads with 30 20 971 Screw-thread paste . Use a new seal and a new nut.


Tightening torque: 25 Nm (18 lbf ft)

37. 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)

38. D223L: Fit the left-hand side cover.

39. Fit the front wing liner section.


40. Fit the connector and hose to the headlamp washer. Fit the front spoiler shield. D223L: Fit the lower engine cover.

41. Fit the front wheels. See Wheels .

Tightening torque 110 Nm (81 lbf ft)

42. Lower the car and fit the bumper shell upper mountings.


43. Check that the upper radiator guides engage their brackets.

44. Fit the quick-release coupling to the clutch slave cylinder. Remove the hose pinch-off pliers. Make sure the connection is secured in the correct position.


45. Bleed the clutch. See Bleeding the clutch hydraulic system in the car .

46. Attach the gear cables to the gearbox.


47. Check the gear positions and adjust if necessary as described under Adjusting gear cables, 6-speed .

48. Fit the reversing light switch connection and the ground cable to the engine mounting.


Tightening torque 18 Nm (13 lbf ft)

49. Fit the battery tray and the bonnet switch connector.


50. D223L: Fit the power steering fluid reservoir with bracket and the cable clamp under the battery tray.

51. D223L: Fit the cover with vacuum tank, etc.

52. Fit the cooling pipe and the battery.


53. Fit the battery cover.


54. Fit the upper engine cover.


55. Remove the wing covers.

56. Carry out Measures after disconnecting the battery .

57. Test drive the car. Check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed.