Automatic Transmission/Transaxle: Service and Repair

LOCALLY MANUFACTURED ADAPTER PLATE FOR TRANSMISSION REMOVAL
The assembled transfer gearbox, automatic gearbox and torque converter is removed from underneath the vehicle. Use a transmission hoist with an adaptor plate for securing the assembly to the hoist. The adaptor can be manufactured locally to the drawing above or purchased from:
Straight Set Engineering,
England.
Tel.01 909 480055

WARNING: When using a transmission hoist it is essential to follow the hoist manufacturer's instructions.

REMOVAL
1. Site vehicle on a four post ramp [hoist].
2. Disconnect battery negative lead.
3. Remove fan cowl securing screws and release cowl from radiator.
4. Loosen securing clip and disconnect air flow hose from plenum chamber.
5. Disconnect stepper motor hose from top of plenum chamber.
6. Disconnect kickdown cable from throttle linkage and release from clipping.
7. Release two gearbox breather pipes from clip located on lifting eye at rear of right hand cylinder head.
8. Remove dipstick from main gearbox oil filler tube.
9. Working inside vehicle detach transfer gear lever gaiter from console, unscrew knob and withdraw gaiter and knob.
10. Raise vehicle on ramp [hoist].





11. Remove drain plugs and drain oil from transfer gearbox and main gearbox.
- Install plugs, tighten to 30 Nm.
12. Detach heat shield at front exhaust pipe to manifold.
13. Disconnect electrical connector to oxygen sensors.
14. Remove catalytic converter assembly.
15. Remove chassis cross-member from under gearbox.
16. Remove heat shield from speedometer cable at transfer gearbox.
17. Remove clamp and disconnect speedometer cable from transfer gearbox.
- Tie cable to one side.
18. Mark for reassembly propeller shaft to transfer gearbox mating flanges.
19. Disconnect rear propeller shaft to output flange, and tie to one side.
20. Repeat instructions 18 and 19 on front propeller shaft to main gearbox.
21. Remove bolts retaining silencer front and rear securing brackets and tie silencer to one side.
22. Disconnect oil cooler feed and return pipes from bottom and side of main gearbox.
23. Release cooler pipes from clamp at engine oil pan and remove distance piece.
24. Blank pipe ends and unions.
25. Move oil cooler pipes clear of transmission and tie aside.
26. Disconnect selector cable from operating lever.
27. Disconnect inhibitor switch at multiplug.
28. Attach adaptor plate to hoist.
29. Remove two bolts from transfer gearbox rear cover.
30. Raise hoist to align adaptor plate with transfer gearbox and transmission.
- Secure to transfer gearbox at rear cover with two bolts removed.
31. Adjust hoist to take weight of transmission.
32. Remove nuts and bolts securing right transfer gearbox mounting bracket to chassis.
33. Repeat for the left mounting bracket.
- Removal of these fixings will also free speedometer transducer bracket
34. Remove right side mounting bracket to flexible mounting rubber retaining nut.
35. Lower hoist until rear brake drum clears passenger footwell.
- Check engine does not crush any components while lowering.
36. Remove clip and clevis pin from park brake lever.
37. Remove clip securing outer brake cable
38. The park brake cable is now free.
39. Disconnect leads from transfer gearbox temperature sensor and differential lock warning light switch.
40. Remove ties securing breather pipes to harness.





41. Remove bell housing access plate complete with gasket.
42. Rotate engine, using crankshaft pulley, until two access holes are visible in drive plate/ring gear assembly through bell housing bottom cover opening.
43. Identify an access hole and bolt hole to aid reassembly.
44. Remove bolts securing drive plate to convertor through access holes.
45. Rotate crankshaft half turn to access and remove remaining bolts.
46. Disconnect oil dipstick tube at main gearbox.
47. Remove bolt at bell housing and detach dipstick tube.
- Cap and plug pipe end and union.
48. Position hoist jack channel under engine and support using a wooden block.
49. Remove bell housing to engine securing bolts, also detach harness bracket from bell housing.
50. Ease transmission rearwards to allow access to secure torque converter in bell housing.
51. Lower hoist and complete removal of transmission.

INSTALLATION
52. Ensure torque converter is retained in bell housing.
53. Secure transmission to adaptor plate on lifting hoist.
54. Raise hoist and locate transmission with engine.
55. Remove torque converter retainer.
56. Complete attachment of transmission to engine and install bell housing bolts.
- Install the dipstick tube bracket and harness bracket to their respective bolts.
57. Complete installation by reversing removal procedure.
- Note the following important points.
58. Drive plate to torque converter bolts are to be coated with Loctite 290 prior to assembly.
59. Refill transfer and main gearboxes with correct grade oil.
- Fill Transfer Box with 2.30 liters (4.90 US pints) of API GL5 or MIL-L-2105 90W EP gear oil.
- Fill automatic transmission with 9.10 liters (19.20 US pints) of Dexron IID ATF.
60. Check operation of parking brake and adjust as necessary, refer to Brakes and Traction Control