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Gearbox assembly B284

Gearbox assembly B284

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.

5. Remove the cable duct, bonnet switch electrical connection and the electrical centre from the battery tray. Remove the battery tray.


6. Undo the upper bumper shell mountings.


7. Remove the mass air flow sensor connector.


8. Remove the hose from the secondary air pump.

9. Remove the vacuum hoses

10. Remove the air filter cover and the hose between the mass air flow sensor and the turbo.

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

12. Raise the car.

13. Remove the front wheels.

14. Remove the spoiler shield. CV: Remove Chassis reinforcement, front subframe, CV

15. Secure the radiator core with the straps.

16. Remove the rear catalytic converter.

Important

Take care so as not to crack the flex bellows.



17. Remove the engine torque rod from the subframe.


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


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

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

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


22. Open the clamps holding the power steering pipe to the subframe.


23. Place 83 95 311 Trolley lift , 83 94 801 Parent fixture , 83 95 188 Basic fixture , 83 95 170 Adapter (4 pcs) and 83 96 137 Centring tool, subframe - body under the vehicle. Position the locating pins and adjust the height of the adapters for even pressure.


24. Remove the subframe bolts and the rear brackets.


25. Lower the subframe slightly (approx. 65 mm).

26. Remove the anti-roll bar from the subframe.

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

28. Lower the subframe and move away the trolley lift.

29. Remove the rear torque rod bracket from the gearbox.


30. Remove the front torque rod bracket from the gearbox.


31. Place a receptacle under the car and drain the transmission fluid. Refit the oil plug.

Tightening torque, drain plug 50 Nm (37 lbf ft)


32. Loosen the left-hand drive shaft using 87 92 616 Removal tool, drive shafts .

33. Hang up the shaft with 83 95 212 Strap .

34. Lower the car to the floor.

35. Lift up the expansion tank.


36. Remove the upper heat shield from the catalytic converter.


37. Remove the lower heat shield from the catalytic converter.


38. Remove the turbo delivery hose from the turbo.


39. Remove the cable duct from the gearbox.


40. Remove the gear cables from the gear selector arms.


41. Remove the cables from the cable retainers by pulling back on the lock sleeves.

42. Unplug the connector of the reversing light switch and detach the gearbox ventilation hose.

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

44. Remove the upper bolts from the gearbox. Use 32 025 063 Special socket .


45. Fit 83 94 850 Lifting beam and 83 95 287 Holder with 32 025 037 Hook for lifting beam on the engine. Take the weight off the engine and gearbox.


46. 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.


47. Disconnect the ground lead.

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

49. Raise the car and fit 87 92 608 Holder for single-column lift onto a column jack.

50. Fit 87 92 608 Holder for single-column lift on a column jack. Adjust and fasten the tool in the gearbox as illustrated.


51. Remove the lower retaining bolt of the secondary air pump.


52. Remove the lower bolts holding the gearbox to the engine.

53. Pull out and let down the gearbox.

Important

The jack can tip over. Be careful.


54. 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.

55. Plug the holes for the drive shafts if the gearbox is being transported or washed. Use 87 92 665 Protective plug, drive shaft hole


To fit


1. Make sure that the two guide sleeves are on the engine and apply grease to the sleeves. Lubricate the primary shaft.

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

3. 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.

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.


Important

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


6. Fit the gearbox to the engine. Tighten the lower bolts between the engine and the gearbox in the sequence illustrated.

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

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


7. Fit the lower retaining bolt of the secondary air pump.

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


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

Important

Fit the drive shaft 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.


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

11. Remove the lifting tool from the transmission and move away the jack. Fit the bolts into the transmission.

Tightening torque 22 Nm (16 lbf ft)

12. Lower the car to the floor.

13. Lift up the unit and fit the bracket on the engine mounting as marked earlier.

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


14. Remove the lifting beam and the holder.

15. Fit the ground cable.

16. Fit the upper bolts between the engine and the gearbox.

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

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


17. Put the wiring harness in place and fit the cable duct to the gearbox.


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

19. Attach the gearbox ventilation hose and plug in the connector of the reversing light switch.


20. Fit the cables to the cable retainers by pulling back on the locking sleeves.

21. Fit the gear cables to the gear selector arms.

22. Raise the car.

23. Fit the rear torque rod bracket to the gearbox.

Tightening torque 80 Nm (69 lbf ft)


24. Fit the front torque rod bracket to the gearbox.

Tightening torque 80 Nm (69 lbf ft)


25. Roll the trolley lift with subframe under the car.

26. Lift the frame. Position the suspension arm ball joints in the steering swivel member and the radiator guide pins. Make sure the upper radiator guides are against their brackets.

Important

Press up the pin carefully.

The groove in the pin must be visible in the screw hole in the spindle housing.

If the rubber gaiter is pressed down, it will not seal properly to the swivel pin.


27. Fit the anti-roll bar to the subframe.


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

29. 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.

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

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

30. Remove the trolley lift.

31. Fit the power steering pipe to the plastic clip on the subframe and the coolant hose to the clip on the subframe.


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

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


33. Fit the engine torque rod to the subframe.

Tightening torque, front nut 60 Nm +90° (44 lbf ft +90°)

Tightening torque, rear bolt 80 Nm (59 lbf ft)


34. Fit the suspension arms to the steering swing member. Use new nuts.

Tightening torque 50 Nm (38 lbf ft)

Important

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



35. Fit the connector and cable clip to the headlamp angle sensor. (Option)

36. Remove the straps.

37. Set up 83 96 145 Centring tool, subframe - engine and 83 96 152 Centring tool, power train with 32 025 059 Support, without the long supports. Check that the engine is correct in relation to the subframe. Remove the centring tool.

38. Fit the rear catalytic converter. Lubricate the threads with 90 513 210 Universal paste .

Tightening torque, exhaust flanges 30 Nm (22 lbf ft)

Tightening torque, exhaust clamp 40 Nm (30 lbf ft)


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

40. Fit the spoiler shield. CV: Fit Chassis reinforcement, front subframe, CV .

41. Fit the wheels. See Wheels .

42. Lower the car to the floor.

43. Fit the upper bumper shell mountings.


44. Fill with 2.2 litres of gearbox oil, see Summary of lubricants and sealants .

45. Fit the filler plug.

Tightening torque 45 Nm (33 lbf ft)

46. Fit the lower heat shield from the catalytic converter.


47. Fit the upper heat shield over the catalytic converter.


48. Fit the expansion tank.


49. Attach the turbo delivery hose to the turbocharger.


50. Fit the battery tray.


51. Fit the cable duct, bonnet switch electrical connection and the electrical centre to the battery tray.

52. Fit the battery.

53. Fit and connect the battery cables.

54. Fit the battery cover.

55. Fit the hose to the mass air flow sensor and the air filter cover.


56. Fit the vacuum hoses.

57. Fit the hose to the secondary air pump.

58. Fit the mass air flow sensor connector.

59. Fit the upper engine cover.

60. Perform Adjusting gear cables

61. Carry out Measures after disconnecting the battery .

62. Remove the wing covers.

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