Removing

Removing and installing automatic transmission
Tools

Preliminary work

WARNING
Burns and scalding through hot components and fluids
^ Allow vehicle to cool down before beginning work

1. Disconnect battery.
2. Remove rear wall cover.
3. Remove the engine-compartment lid.
4. Unscrew fastening nuts for restraining cables and remove restraining cables from cross member.

5. Retaining device P 9624/1 must be screwed to cross member. Then turn spindle upwards and support engine.
6. Remove the starter.
7. Raise the vehicle at the prescribed jacking points.
8. Remove wheels.
9. Remove rear silencer.
10. Remove support plate.

Removing automatic transmission
Removing converter bolts
1. Turn crankshaft to the extent that one of the U4, U5 or U6 bores in the belt pulley is aligned with the centring bore in the crankcase.

3. Insert assembly aid 9596 into starter opening.
4. Unscrew converter fastening screws with 6mm hexagon socket through the openings -arrows- in the assembly aid 9596.
5. Pull locating pins (short) 9595/1 out of the belt pulley.
6. Turn crankshaft by 120° so that one of the U4, U5 or U6 bores in the belt pulley is aligned with the centring bore in the crankcase.

Note:
^ The crankshaft is fixed in defined position by inserting the fixing pin.
^ If the fixing pin can not be inserted, check the correct positioning of the belt pulley in relation to the crankcase.

7. Insert locating pins (short) 9595/1 through the belt pulley in the crankcase housing bore.
8. Unscrew converter fastening screws with 6mm hexagon socket through the openings -arrows- in the assembly aid 9596.
9. Pull locating pins (short) 9595/1 out of the belt pulley.
10. Turn crankshaft by 120° so that one of the U4, U5 or U6 bores in the belt pulley is aligned with the centring bore in the crankcase.

13. Unscrew support for positive crankcase ventilation line on engine transport eyebolt.

14. Push locating pins (long) 9595/1 through the opening in the transmission housing to prevent the transformer from falling out.

Dismantling

1. Pull vacuum line off the switch-over valve.

2. Unscrew vent line on engine transport eyebolt.

3. Loosen fastening screws between anti-roll bar and rear axle carrier side panel and fold anti-roll bar forward.

4. Remove the cross member

Note: Protect drive shafts against mechanical damage (e.g. with rubber hose which has been cut open).

5. Remove drive shafts on transmission side. To do this, unscrew the six Allen screws joining each drive shaft and transmission flange. Counter at the brake disc or activate the parking brake to avoid simultaneous turning.

6. Lever selector cable off the ball pin and disengage from support bracket.

7. Turn connector of transmission socket anticlockwise and pull off.

8. Disconnect the plug connection for the multi-function switch.

9. Unscrew retaining screw between the transmission and the coolant pipe.

10. Clamp shut coolant hoses (flow and return sides) with hose clamp 3094.

11. Unscrew fastening screws between transmission and mount for exhaust system and remove mount for exhaust system.
12. Place collection pan for coolant under the transmission.

13. Unscrew fastening screw between ATF cooler and coolant line and pull coolant line out of ATF cooler.

14. Unscrew fastening screw between ATF cooler and coolant line and pull coolant line out of ATF cooler.

Removing automatic transmission

DANGER
If the supports are folded down, the vehicle will roll off the platform lift when it is lowered.
^ Ensure that the platform is prevented from lowering.
^ Remove supports before lowering.

Note: When pulling out the automatic transmission, ensure that the transmission support has already been loosened.

1. Place transmission jack under transmission and fasten fixing strap.

2. Unscrew fastening screws between the transmission and the transmission support.

Note: The fastening nuts of the transmission support must never be loosened at the hydraulic mount because otherwise the transmission brackets will be damaged.

3. Unscrew fastening screws between the body and the hydraulic mount -arrow-.
A - Transmission support
B - Hydraulic mount
C - Fastening nut (never loosen)

4. Unscrew fastening screws -1 to 7- and pull out transmission to the rear and downward.