Removal and Replacement
Transmission, removal
Special tools:
999 5033 SUPPORT 999 5033 Support
999 5006 LIFTING BAR 999 5006 Lifting Bar
999 5045 COMPRESSION HOOK 999 5045 Compression Hook
999 5460 Lifting hook 999 5460 Lifting Hook
999 5461 COUNTERHOLD 999 5461 Counterhold
999 5488 PLUGS 999 5488 Plugs
999 5462 Jimmy tool 999 5462 Jimmy Tool
999 5463 FIXTURE 999 5463 Fixture
999 5534 LIFTING FORK 999 5534 Lifting Fork
999 5540 COUNTERHOLD 999 5540 Counterhold
999 5972 FIXTURE 999 5972 Fixture
998 5972 JACK 998 5972 Jack
Note! Illustrations only show RHD and turbo models where these differ.
Set steering wheel position
Release steering wheel adjustment lever.
Push steering wheel in as far as it will go and turn it upwards as far as possible. Lock steering wheel in position.
Put shift lever in neutral position.
Remove:
- Battery.
- ACL and air intake.
- Disconnect timing valve from ACL. Turbo models only:
- Battery shelf.
- ACL bracket retaining screws.
Turbo models only:
Disconnect clip from turbo air pipe and hose from pipe.
Remove air intake between air filter and turbo unit.
Remove:
- Selector cables from bracket and levers.
- Selector link plate by tapping out pin.
- Backup (reverse) light switch connector.
Turbo models only:
Remove control pulley cover.
Disconnect:
- Oil coolant hose to engine oil coolant. Upper oil coolant hose to engine oil cooler.
- Disconnect clutch slave cylinder from transmission.
Remove:
Detach clutch slave cylinder from transmission.
Remove circlip.
Caution! Ensure that boot stays in place on cylinder.
Remove:
- GND lead from transmission.
- Cable tie(s) from engine cable harness.
Slacken the nut on the rear engine mounting/ splashguard a few turns.
Remove:
- The five bolts holding the starter motor/gearbox.
Lift the coolant expansion tank clear of the bracket and let it hang free.
Only cars with EGR:
Cars with EGR only:
Disconnect hoses from control valve (A)
Remove the bolt holding the steady bar/torque arm to engine.
Install lifting fork 999 5534 LIFTING FORK 999 5534 Lifting Fork on torque rod - engine
Install:
- support 999 5033 SUPPORT 999 5033 Support on fender edges
- lifting beam 999 5006 LIFTING BAR 999 5006 Lifting Bar on support. Position beam directly over lugs on lifting fork.
- lifting hook 999 5460 Lifting hook 999 5460 Lifting Hook. Tighten the hook approx. 5mm
- Note the measurement between lifting beam and spark plug cover.
Remove:
- Remove:
- ABS sensor from wheel spindle (left-hand side).
Caution! Do not undo connector.
Disconnect:
- Brake pipe and ABS cable brackets (both sides). Unhook brackets and let them hang free.
Remove:
- Front plastic nut(s) from LH wing (fender) liner, and any TORX bolts.
- Free the nuts of the locking tabs. Install counterhold 999 5461 COUNTERHOLD 999 5461 Counterhold (4 wheel studs) or counterhold 999 5540 COUNTERHOLD 999 5540 Counterhold (5 wheel bolts) and remove nut.
Undo driveshaft end from hub.
Knock end of drive shaft approx. 10-15 mm into the hub. Use plastic or copper mallet.
Remove:
- Both front splashguard bolts. Push guard forward so locating pins on back come loose. Disconnect guard at front and remove.
- Splashguard under engine (earlier models). Splashguard under engine (earlier models).
- Nuts to link arms/ball joints (both sides). Unhook link arms from ball joints.
Caution! Take care not to damage ball joint bellows (gaiters).
Disconnect and unhook link arms from anti-roll bar (both sides)
Remove:
- Cable pipe mounting bolt from subframe and unhook pipe from frame.
Disconnect canister holder and hoses from subframe
- Snip through cable tie to hoses and hang canister from body.
Disconnect the exhaust gas tie behind the three-way catalytic converter (TWC).
Remove:
- oil pipe bracket bolts
- the two bolts holding the steady bar bracket to the transmission.
Drain oil from transmission.
Caution! Only if replacing transmission or changing oil. Tighten plug to 35 Nm.
RH drive cars only:
Remove impact absorber over steering gear. (2 bolts.)
Disconnect RH driveshaft
- Remove bearing cap.
- Pull out driveshaft innards, bending McPherson strut back.
Caution! Take care not to damage transmission seals.
- Install plug 999 5488 PLUGS 999 5488 Plugs.
- Let driveshaft rest on subframe and oil pipe.
Remove bolts from front engine mounting subframe
- Slacken bolts holding steering gear to engine mounting about one turn.
Remove nuts holding steering gear to subframe (5).
RH drive cars only:
- Remove nut (A) to impact absorber/subframe.
Disconnect subframe from car.
- Position mobile jack 998 5972 JACK 998 5972 Jack to support the left-hand side of the sub-frame, slight pressure.
- Remove fixing bolts holding subframe brackets on both sides.
- Unscrew the two bolts holding the subframe to the body on the right-hand side by about 15 mm .
- Remove bolts on left-hand side.
RH drive cars only:
Lower subframe approximately 100 mm.
Check that the five steering gear bolts and crash guard bolts come away from frame.
Remove anti-roll bar bearing cap bolts (left-hand side). Undo bolts on right-hand side until they are only held by a few turns.
Lash anti-roll bar to steering gear as shown in picture.
Lower subframe
Caution! Check that steering gear bolts come away from subframe. Check that MacPherson strut comes away from RH driveshaft bellows (gaiter).
Remove jack
Let frame hang free from bolts on right-hand side.
Hang steering gear on left-hand side using hook 999 5045 in hole in frame member flange.
Remove bolts to engine mounting steering gear and nut on top of engine mounting. Remove engine mounting.
Caution! Check that steering gear is hanging properly on hook so that lower steering wheel shaft section does not slip out of steering column.
Tape driveshaft end to oil pipe
Disconnect:
- HO2S cable terminals from cover.
- Speedometer connector and cable.
Remove:
- Rear engine mounting cover.
- Rear mounting from transmission.
Remove left-hand driveshaft
- Twist MacPherson strut and pull out. Tap driveshaft end with plastic or copper mallet and pull driveshaft end out of hub.
- Remove driveshaft from transmission. Use jimmy bar 999 5462 Jimmy tool 999 5462 Jimmy Tool between transmission and inside of drive shaft. see workshop guide bulletin/tool bulletin.
Caution! Treat driveshaft seals and bellows (gaiters) with care.
Install plug 999 5488 PLUGS 999 5488 Plugs in transmission.
Clean spline assembly (hub-driveshaft) of metal glue.
Lower engine and transmission
- Lower with lifting hook 999 5460 Lifting hook 999 5460 Lifting Hook until the distance between the lifting beam and sparking plug cover is approx. 320 mm.
Caution! Do not lower engine too far, as exhaust pipe may push down on steering gear.
Caution! Check that no leads or hoses are pinched or stretched and that the engine dipstick tube comes away from the fan.
Install universal tool 999 5972 and transmission fixture 999 5463 on jack
Install transmission fixture in transmission with torque rod retainer bolts.
- At the same time install support plate (marked 999 5463 FIXTURE 999 5463 Fixture ) on the fixture, modified according to Workshop Guide.
- Jack up engine.
Remove remaining bolts holding transmission to engine (7)
Remove transmission
- Pull gearbox straight out from engine.
Caution! Check that transmission actually comes straight away from the engine without any breaks in the clutch plate centre.
- Lower jack and move transmission away.