Automatic Transmission/Transaxle: Service and Repair

Remove

1. Position vehicle on four post lift.
2. Disconnect battery negative lead.





3. Petrol Vehicles: Release clips securing cooling fan cowling. Remove cowling.





4. Remove bolt securing gearbox filler tube to engine.
5. Remove window switch pack.





6. Release handbrake. Remove handbrake cable clevis pin.
7. Release hand brake cable from grommet in tunnel.
8. Raise lift. Drain gearbox and transfer box fluids.
9. Remove exhaust front pipe. Diesel Vehicles: Remove chassis cross member.





10. Remove 4 bolts securing transmission mounting assembly. Remove assembly.
11. Position transmission lift adapter LRT-99-007. Secure to transmission mounting bracket location with bolts. Remove transmission jack from under brake drum.





12. Remove 4 bolts securing rear propeller shaft guard. Remove guard.
13. Mark transfer box and propeller shaft flanges to aid re-assembly.
14. Raise one wheel on each axle to allow rotation of propeller shafts.





15. Remove 4 bolts from each flange. Disconnect propeller shafts. Tie aside.
16. Lower gearbox for access.

CAUTION: Place wooden block between axle case and sump to support engine.





17. Disconnect gear selector cable trunnion from gearbox lever. Remove 2 bolts securing selector cable abutment bracket to gearbox. Place selector cable aside.





18. Disconnect 2 Lucars from transfer box fluid temperature sensor.
19. Disconnect multiplugs from High/Low motor and output shaft speed sensor.
20. Disconnect multiplugs from gear selection position switch and gearbox speed sensor.
21. Release harness from clips.
22. Remove bolt from clamp securing gearbox cooler pipes to engine.





23. Disconnect transmission cooler pipes. Remove O-rings and discard. Plug pipes and connections.
24. Release fluid filler pipe from gearbox. Remove O-ring and discard. Plug pipe and connection.
25. Disconnect breather pipes from gearbox and transfer box. Plug Pipes and connections.
26. Remove 3 bolts securing converter housing lower access cover. Remove cover. Collect gasket.





27. Remove 9 bolts securing converter drive plate access cover. Remove cover.
28. Mark drive plate and converter to aid re-assembly.





29. Remove 4 bolts securing drive plate to converter.





30. Remove 8 bolts securing converter housing to engine.
31. Remove transmission assembly.

CAUTION: Ensure converter does not become detached from gearbox.

32. Fit retaining strap to converter. Secure with 2 nuts and bolts. Do not carry out further dismantling if component is removed for access only.
33. Lower transmission assembly from vehicle.
34. Attach lifting eyes to transmission.
35. Attach hoist to lifting eyes. Take weight of transmission.
36. Remove lift adapter. Hoist transmission assembly onto bench.
37. Fit lifting eye to transmission brake drum. Raise gearbox on end.

CAUTION: Position packers beneath bell housing extension to provide clearance for input shaft.





38. Remove 6 bolts securing transfer box to gearbox. Release from 2 ring dowels. Remove transfer box.
39. Ensure mating faces are clean.
40. Place gearbox on end. Position transfer box.
41. Engage transfer box to ring dowels. Secure to gearbox with bolts. Tighten to 45 Nm (33 ft. lbs.)
42. Place transmission on side. Fit lifting eyes.
43. Attach transmission to lift adapter. Secure with bolts.
44. Detach hoist. Remove lifting eyes.

Refit
45. Ensure converter spigot and mating faces are clean.
46. Remove converter retaining strap.
47. Position transmission to engine. Secure with bolts. Tighten to 42 Nm (31 ft. lbs.)
48. Position drive plate to converter. Align marks. Secure with bolts. Tighten to 45 Nm (33 ft. lbs.)
49. Position converter access panels. Use a new gasket with lower panel. Secure panels with bolts.
50. Remove plugs from breather pipes and connections.
51. Using new sealing washers, secure breather pipes to gearbox and transfer box with banjo bolts.
52. Fit new seals to fluid filler and cooler pipes. Connect pipes to transmission. Tighten to 30 Nm (22 ft. lbs.)
53. Fit clamp to cooler pipes. Secure to engine with bolt.
54. Route gearbox harness. Secure with clips.
55. Connect multiplugs to High/Low motor and output shaft speed sensor.
56. Connect multiplugs to gear selection position switch and gearbox speed sensor.
57. Connect Lucars to transfer box fluid temperature sensor.
58. Align harness bracket to gearbox.
59. Position selector cable abutment bracket to gearbox. Secure with bolts.
60. Raise transmission. Support under brake drum with transmission jack.
61. Remove transmission lift adapter. Remove lift.
62. Position transmission mounting assembly. Secure with bolts. Tighten to 45 Nm (33 ft. lbs.)
63. Adjust gear selector cable.
64. Raise one wheel on each axle to allow rotation of propeller shafts. Position shafts to transfer box flanges. Align marks.
66. Secure shafts with nuts and bolts. Tighten to 48 Nm (35 ft. lbs.)
67. Fit propeller shaft guard. Secure with bolts.
68. Guide hand brake cable through grommet in transmission tunnel.
69. Diesel Vehicles: Fit chassis cross member.
70. Fit exhaust front pipe.
71. Fill transfer box with oil.
72. Lower Vehicle
73. Connect handbrake cable to lever.
74. Fit window switch pack.
75. Position gearbox filler tube to engine. Secure with bolt.
76. Petrol Engines: Position cooling fan cowl. Secure with clips.
77. Fill gearbox with fluid.
78. Reconnect battery negative lead.