Transaxle, Remove and Replace
Removal and fitting of ZF 4 HP 18 automatic transmission is shown in a car with a B234 engine, equipped with turbo and air conditioning (A/C).
Important: Cabling, hoses, leads etc. are attached with hard plastic cable ties. After these are tightened, they are cut, leaving sharp edges at the fixing points. Be careful not to cut yourself on these sharp ends on the cable ties.
Removal
1 Place a protective cover over the wings to prevent the paint work becoming damaged or dirty.
Engine version V6 B308
Remove the covers over the engine.
2 Detach battery cables.
3 Remove battery.
4 Remove the clip holding the throttle cable in the grommet and move the cable to one side.
5 Detach the front electrical distribution box and move it to one side.
6 M1994 only
Detach the positive terminal without removing the cables.
7 M1994 only
Remove the two clips from the positive lead on the battery tray.
8 M1994 only
Unplug the connector from the ABS control module.
From M1995
9 Detach the cruise control cable from its lever.
10 Detach the positive terminal from the battery tray and undo the positive lead clip. Pull the vacuum hose out of its clips on the battery tray.
11 Slightly lift the battery tray and disconnect the cruise control connector.
12 Remove the battery tray with the cruise control module and cable.
13 Remove the battery tray.
Engine version V6 B308
14 Detach the throttle cable and kick-down cable from the bracket, unclip the control rod, detach the bracket and move it to one side.
15 Undo the hose clips between the intake manifold and inlet pipe and between the resonating chamber and the mass air flow sensor and slightly raise the intake manifold. Disconnect the vacuum hoses and electrical connector and remove the manifold and resonating chamber.
16 Remove the hose between the turbocharger delivery pipe and the transmission. Then plug the hole in the transmission.
17 Detach the hose from the bypass valve.
18 Unplug the intake air temperature connector on the turbocharger delivery pipe.
19 Undo the hose clips and remove the turbocharger delivery pipe.
20 Remove the kick-down cable from the throttle body.
21 Remove the selector arm from the transmission. Do not split the universal joint.
22 Remove the banjo screw for the hose to the in-take side of the fluid cooler on the back of the transmission. Then plug the hole.
23 Undo the nut and press out the selector cable rubber bushing from its bracket on the gear case.
24 Place a receptacle under the car so that the fluid can be collected.
25 Remove the banjo screw for the hose to the outlet side of the fluid cooler on the front of the transmission and plug the hole.
26 Detach the battery ground cable from the transmission.
27 Unplug the connector on the cable for the vehicle speed sensor.
28 Remove the screws in the partition surface which are accessible from above, except the front screw. One of these screws is also a retaining screw for the starter motor.
29 Remove the screws in the upper end of the support in the wheel housing.
30 Place lifting beam 83 93 977 on the wheel housings. Make sure that the beam is in contact with the edges of the wings. Place the hook in the engine's lifting eye and lightly tension using the beam wing nuts.
31 Raise the car.
32 Remove the left-hand front wheel.
33 Remove the wheel arch trim and the front part of the wing liner.
34 Remove the left-hand and centre air deflector.
35 Remove the cover plate from the transmission.
36 Remove the screws securing the torque converter to the drive plate. Access is via the hole for the starter motor.
In cars with V6 engines the plastic plug under the starter motor must first be removed.
Note: The motor must be turned in order to access the screws. The spanner is inserted beside the right-hand wing liner which has been detached on the lower edge.
37 Fit holder 87 92 293 which secures the torque converter in position when the transmission is removed. The holder is fitted with an M10 screw.
38 Remove the remaining screws in the partition surface (accessible from underneath).
39 Remove the three screws securing the ball joint to the suspension arm.
40 Remove the nut on the anti-roll bar bracket in the suspension arm. Remove both the screws securing the anti-roll bar bearing.
41 Remove the nut from the screw in the front engine mounting. Keep the two washers.
42 Remove the support at the wheel housing. The upper part has already been detached.
43 Undo the screw in the front joint of the subframe and remove the two screws holding the joint.
44 Undo the screw in the rear joint of the subframe and remove the two screws holding the joint. One of these screws also holds the steering gear.
45 Remove the two screws in the front corner and the four in the rear corner of the subframe. Carefully lower the subframe. Keep the metal clip.
46 Remove the screws from both joints and remove the subframe.
47 Remove the clip from around the universal joint gaiter. Clips with no screw must be cut off using pliers. Take care not to damage the rubber gaiter. Separate the joint and let the shaft hang down. Place the protective cover on the universal joint and driver.
Important: Keep clean when working with universal joints. Sand or dirt, even in small quantities, considerably reduces the service life of universal joints.
48 Lower the car.
49 Remove the bleeding plug from the topside of the transmission.
50 Fit lifting sling 87 91 451 to the transmission and insert lifting cable 87 92 442 in the lifting eye.
51 Hook the cable onto the lift and tension it.
52 Remove the last screw from the partition surface, tighten and lower the transmission.
Important: If the transmission is to be dispatched or exchanged, the torque converter must always be attached using a transit support.
Warranty and part cost are not reimbursed if the transit support is not fitted.
When making a claim for reimbursement, the test form should be enclosed.
Fitting
Before starting to fit. Make sure that the intermediate shaft is in position on the right-hand driver and that the aluminium tube has been pressed onto the seal.
From this point, the car must be down and the engine suspended in a lifting beam.
1 The torque converter must be positioned so that the screw holes for the driver plate align with the holes in the torque converter.
Attach the torque converter using holder 87 92 293 to a detached transmission.
2 If the engine mounting has been removed from the transmission:
- The engine mounting must be fitted so that both arrows are aligned.
3 Insert locating stud 83 92 128 in the front hole in the partition surface in the engine body.
4 Detach the bleeding mechanism. Then fit lifting sling 87 91 451 to the transmission and fit cable 87 92 251. Hook the cable into the sling and lift the transmission into fitting position.
5 Apply grease to pin. Position the transmission on the locating stud in the partition surface and check that the pin on the torque converter is guided into position.
6 Fit a screw in the partition surface. Check that the aluminium tube is sealing against the transmission.
7 Remove the locating stud and lifting sling.
8 Screw the bleeding mechanism on to the transmission.
9 Attach the two screws in the upper end of the support in the wheel housing. Do not tighten.
10 Raise the car.
11 Remove the protective covers and fill the driver with grease. Then fit the drive shaft.
12 Fit the universal joint rubber gaiter with a new clip (if clip cannot be reused).
Important: Keep clean when working with universal joints. Sand or dirt, even in small quantities, considerably reduces the service life of universal joints.
13 Suspend the subframe and attach the two joints, each with one screw.
14 Raise the subframe. Make sure that the metal clip on the rear of the subframe is correctly positioned.
15 Fit the screw in the engine mounting and make sure that the washers are correctly positioned. Do up the nut.
16 Fit the two screws to the front corner of the subframe.
17 Fit the four screws in the rear corner of the subframe.
18 Then fit the two screws securing the rear joint. One screw also holds the steering gear.
19 Fit the two screws holding the front joint.
20 Torque tighten all screws in the subframe (12 screws).
Tightening torque, front attachment: 55 ± 8 Nm (37 ± 5 lbf ft).
Tightening torque, rear attachment: 55 ± 8 Nm (41 ± 6 lbf ft).
21 Fit the lower end of the wheel housing support to the subframe.
Tightening torque: 50 ± 7 Nm (37 ± 5 lbf ft).
22 Fit the screws securing the anti-roll bar bearing.
Tightening torque: 29,5 ± 4,5 Nm (21,5 ± 3,5 lbf ft).
23 Fit the three screws securing the ball joint to the suspension arm. Use new locknuts.
Tightening torque: 30 ± 4 Nm (22 ± 3 lbf ft).
24 Fit the nut securing the anti-roll bar bracket to the suspension arm.
Tightening torque: 23,5 ± 3,5 Nm (17,5 ± 2,5 lbf ft).
25 Remove holder 87 92 293 securing the torque converter.
26 Fit (but do not tighten) the three screws in the torque converter. Then torque tighten the screws. Use Loctite 242 locking compound.
Tightening torque: 58 ± 9 Nm (43 ± 6 lbf ft).
27 Engine version V6 B308:
- Refit the plastic plug under the starter motor.
28 Fit the transmission cover plate.
29 Torque tighten remaining screws in the partition surface which are accessible from underneath.
Tightening torque: 70 ± 20 Nm (50 ± 15 lbf ft).
30 Lower the car and remove the lifting beam.
31 Fit the nut to the engine mounting screw and tighten.
Tightening torque: 70 ± 21 Nm (50 ± 15.5 lbf ft).
32 Tighten the two screws for the support at the wheel housing.
Tightening torque: 25,5 ± 3,5 Nm (19 ± 2,5 lbf ft).
Torque tighten remaining screws in partition surface. Screws are accessible from above.
Tightening torque: 70 ± 20 Nm (50 ± 15 lbf ft).
33 Fit the selector lever rubber bushing in the bracket on the gearcase, tighten the nut and fit the selector arm.
Tightening torque: 18 ± 3 Nm (10 ± 2.2 lbf ft).
34 Engine version V6 B308
a. Align intake manifold with the resonating chamber, connect the vacuum hoses and the wiring harness and tighten the hose clips against the intake pipe and the mass air flow sensor.
b. Do up the accelerator linkage bracket, connect the control rod, connect the throttle cable and the kick-down cable.
35 Fit the kick-down cable to the throttle body.
36 Adjust the kick-down cable. Adjustments
37 Plug in the connector on the cable for the vehicle speed sensor.
Important: Check that the selector cable, kick-down cable and the cable to the speedometer are correctly located.
38 Fit the battery ground lead to the transmission.
39 Fit the turbocharger delivery pipe.
40 Fit the hose to the charge air bypass valve.
41 Refit the connector to ihe temperature sensor.
42 Fit the hose between the turbocharger delivery pipe and the transmission.
43 From M 1995
a. Hold the battery tray in position and connect the cruise control. Do up the battery tray screws.
b. Refit the cable conduit, push the vacuum hose onto the battery tray and refit the positive terminal and positive cable clip.
c. Connect the cruise control cable to the lever.
44 M1994 only
Fit the battery tray.
45 M1994 only
Fit the connector to the ABS control module and clip on the cable.
46 M1994 only
Fit the positive cable to the battery tray using the two clips.
47 M1994 only
Fit the positive terminal.
48 Fit the front electrical distribution box.
49 Fit the battery.
50 Engine version V6 B308
Fit the engine covers.
51 Fit the throttle cable to the throttle body.
52 Connect battery leads.
53 Fit the left-hand and centre air deflectors.
54 Fit the front part of the wing liner.
55 Fit the wheel arch trim:
Check that the wing liner on the right-hand side is fitted if it has been removed.
56 Fit the wheel.
Tightening torque: 120 Nm (89 lbf ft).
57 Fill with automatic transmission fluid. Then clean the transmission cooling system using flushing equipment 87 91 824.
58 Check and adjust selector lever play. Adjustments
59 Remove the covers.
60 Check fluid level in the transmission and test drive the car.
Important: After carrying out internal repairs on the transmission or after changing to a new transmission, flushing equipment 87 91 824 should be connected to the transmission cooling system before starting the engine. Otherwise, there is a risk of damage.