Installing Transmission
NOTE: This method of removing and installing the transmission applies to all 850 variants. Before starting work on the 850 AWD transmission, refer to Transfer Case/Bevel Gear replacement section. Service and Repair
NOTE: Removing and installing the 850 AWD special rear engine mounting is contained in this method.
NOTE: The illustrations in this section show a LHD car. RHD and turbocharged versions are described only where they differ.
NOTE: Special tools necessary: 951 2050, 998 5972, 999 5006, 999 5033, 999 5045, 999 5460, 999 5463, 999 5534, 999 5540, 999 5972
Check Before Installing Tie Strap
- Attach a tie strap round the clutch fork as illustrated
Check That:
- transmission cover and engine mating surfaces are clean
- guide sleeves on the engine are in place and undamaged.
- Apply a light coating of grease in the holes for the guide sleeves (on the transmission).
CAUTION: Do not apply grease to the primary shaft and the throwout bearing sleeve.
CAUTION: Check that guide sleeves on engine are in place.
Installing Engine Mounting
- Install engine mounting.
- Tighten to 50 Nm (37 ft.lb.).
Installing Transmission
- Use the transmission fixture and the mobile jack to line up the transmission with the engine.
CAUTION: Ensure that the transmission goes straight into the engine without causing stresses in the clutch driven plate center.
- Install screws (7) and tighten alternately. Start with screws A and B which go through the guide sleeves. Lightly tighten screws alternately. Check that transmission and engine are in contact all the way around. Then tighten screws alternately (as above) to 50 Nm (37 ft.lb.).
NOTE: It is important that screws are tightened correctly. Uneven tightening may cause transmission noise.
- Remove transmission fixture and mobile jack from transmission.
Installing Engine And Transmission
- Lift engine and transmission
- Adjust lifting hook 999 5460 to the distance noted between lifting beam and spark plug cover according to DA8.
- Ensure that no cables or hoses are trapped.
Installing Rear Engine Mounting
- Install the rear engine mounting on the transmission Install mounting on transmission (3 screws). Tighten two rear to 50 Nm (37 ft.lb.). Remove the front screw again. Install the cover using the mounting screw. Press the cover up against the mounting and tighten the screw to 50 Nm (37 ft.lb.).
Installing Engine Pad
- Install engine pad. Use a new nut.
- Align the engine pad locating pin with the cover and install nut loosely.
- Install engine pad - steering gear screw. Do not tighten the screw.
- Remove support hook 999 5045.
Install:
- heated oxygen sensor (HO2S) cable with clamps on cover.
- vehicle speed sensor (VSS) connector and cable.
On Right-hand Drive Cars Only:
- Remove the tape from the drive shaft and let the shaft rest on the oil pipe.
- Raise sub-frame to 100 mm (3.937") from car body. Locate steering gear and crash guard in sub-frame. Install left anti-roll bar bearing with bearing cap and tighten both bearing caps to 50 Nm (37 ft.lb.).
Installing Sub-frame
Caution: Use new screws (4 x M14). Lubricate screw threads. Carefully locate steering gear screws in holes in sub-frame.
- Start on left-hand side. Lift sub-frame with mobile jack. Locate steering gear screws in sub-frame. Install the sub-frame and support bracket screws. Tighten screws to 105 Nm + 120° (77.4 ft.lb. + 120°, and then screws to sub-frame bracket to 50 Nm (37 ft.lb.). Use a protractor 951 2050.
Move the mobile jack to the right-hand side, remove existing screws and repeat operation.
Removing Lifting Hook, Lifting Beam, Fender Edge Supports, And Lifting Fork
- Tighten rear engine pad - splash guard nut to 50 Nm (37 ft.lb.).
Installing Engine Mounting Sub-frame Screws
- install engine mounting - sub-frame screws Tighten to 50 Nm (37 ft.lb.).
Installing Steering Gear, Sub-frame - Front Engine Pad
Install:
- new steering gear nuts (5) and tighten to 50 Nm (37 ft.lb.).
- screw for sub-frame - front engine mounting. Tighten front and rear engine pad screws to 50 Nm (37 ft.lb.).
Installing Torque Rod Mounting
Install:
- torque rod mounting to transmission with new screws. Use a protractor 951 2050 and angle-tighten to: 18 Nm + 90° (13.3 ft.lb. + 90°) (early versions), M8 35 Nm + 40° (25.8 ft.lb. + 40°) (later versions), M10.
- oil pipe bracket screws. Tighten to 25 Nm (18.5 ft.lb.).
- Tighten exhaust pipe clamp Twist pipes when tightening.
Installing Right Drive Shaft
- Install right drive shaft to transmission
CAUTION: Take care not to damage the sealing ring in the transmission or the boot on the drive shaft.
- Install bearing cap and tighten to 25 Nm (18.5 ft.lb.).
On Right-hand Drive Cars Only:
Install:
- crash guard/sub-frame nut. Tighten to 50 Nm (37 ft.lb.). Use a new locknut.
- steering gear crash guard. Two screws. Tighten to 80 Nm (59.0 ft.lb.).
Installing Drive Shaft
- Install left drive shaft.
- Ensure that the ABS sensor pulse wheel on the driveshaft is free of dirt.
- Press in drive shaft firmly so that the snap ring engages in its groove in the differential gear. Check by pulling carefully on the drive shaft CV joint housing.
CAUTION: Ensure that the seal ring in the transmission and the boot on the drive shaft are not damaged.
Aligning Drive Shaft With Hub
- Apply metal adhesive 1161370-0 to the drive shaft splines. See illustration. Fold out and turn spring strut. Align drive shaft with hub.
- Use holder 999 5563 to press down control arm.
- Install drive shaft nut by hand.
Early type (M2O): Use a new oiled nut.
Late model (M22): The old nut can be reused. Oil the nut.
- Remove holder.
NOTE: Take care not to damage the drive shaft boot.
Installing Control Arm/ball Joint
Install On Both Sides:
- control arm/ball joint to stub axle. Remove socket 999 5562 from ball-joint. Ensure that the ball joint pinion groove lines up with the screw hole in the stub axle. Use new lock nuts on screws. Tighten to 50 Nm (37 ft.lb.).
- anti-roll bar link. Use new lock nuts. Tighten to 50 Nm (37 ft.lb.).
Tightening Drive Shaft Nut
- Tighten left drive shaft nut.
- Use counterhold 999 5461(4 wheel studs) or 999 5540 (5 wheel studs) and protractor 951 2050.
- Tighten nut to 120 Nm + 60° (88.5 ft.lb. + 60°).
- Remove counterhold.
Lock nuts, early type (M20):
- Knock down the nut locking flange into the groove on the drive shaft.
Lock nut, late model (M22):
- The nut is self-locking.
Installing Brake Pipe Bracket
- Install brake pipe/ABS cable bracket on both sides.
CAUTION: Check that the ABS sensor seating is absolutely clean.
- Lubricate sensor holes with wheel bearing grease, P/N 1161241-3.
- Clean the ABS sensor with a soft brush. Then install it in the stub axle and tighten to 10 Nm (7.4 ft.lb.).
- Install plastic nut and TORX screws to left-hand side tender liner. (TORX screws discontinued on later versions.)
- Check transmission oil level. Tighten plug to 35 Nm (25.8 ft.lb.).
Installing Cable Conduit And Engine Cover
Install:
- cable conduit on sub-frame.
- EVAP canister. Clamp hoses to sub-frame with tie straps. Hook hoses onto the sub-frame.
- splash guard under engine. (Early type).
Installing Front Splash Guard And Wheel
Install:
- front splash guard, press into place at front. Press forward and press upward at rear so that guide spigot is seated in slot. Install screws.
- wheels according to Tightening wheel stud section
Installing Transmission/engine, Transmission/starter Motor Screws
- Install the five screws between the transmission/engine and transmission/starter motor
CAUTION: Do not forget the cooler hose bracket.
- Tighten transmission/engine screws to 50 Nm (37 ft.lb.). Tighten transmission/starter motor screws to 40 Nm (29.5 ft.lb.).
Installing Electrical Components, Clutch Slave Cylinder And Circlip
Install:
- wiring clamp(s)
- ground lead
- clutch slave cylinder
- circlip.
CAUTION: Carefully remove the temporary tie strap around the throwout fork.
Installing Transmission Components
Install:
- back-up (reversing) light switch connector.
- outer selector lever and split pin.
- selector cables on bracket mounting.
CAUTION: The outer mounting and outer selector cable are marked in yellow.
- Lubricate selector lever lugs with grease P/N 1161241-3. - selector cables to levers.
- two washers and two clips.
Installing Torque Rod Components
Install:
- ground strip on firewall.
- torque control arm/torque rod screw and nut.
CAUTION: Use a new screw and new locknut
Locknut Pin:
- M8 (on early version) 948645-7
- M10 (on late version) 971098-9
NOTE: On later version the locknut is standard.
Tighten to:
- M8 18 Nm (13.2 ft.lb.) and angle-tighten to 120°
- M10 35 Nm (25.8 ft.lb.) and angle-tighten to 90°
Only Cars With Turbocharged Engines:
Install:
- engine oil cooler hose.
- intake pipe to throttle body.
- throttle pulley cover.
- charge air pipe hose and clamp.
- turbocharger (TC) intake.
Installing Engine Parts
Install:
- expansion tank.
- air cleaner (ACL) housing bracket screws.
- battery shelf.
- turbocharger (TC) control valve on air cleaner (ACL) housing (turbocharged engines only).
- air cleaner (ACL) housing with fresh air hose and connections.
- battery.
- regulator valve hoses. (Cars with an EGR valve only).