Removing 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. To work on the right drive shaft refer to Transfer Case/Bevel gear replacement section.
NOTE: The illustrations in this section show a LHD car. RHD and turbocharged versions are described only where they differ.
NOTE: Special tools necessary: 999 5006, 999 5033, 999 5045, 999 5460, 999 5461, 999 5462, 999 5463, 999 5488, 999 5534, 999 5540, 999 5562, 999 5656, 998 5972, 999 5972
Adjusting Steering Wheel Position
- Slacken steering wheel adjusting lever.
- Press steering wheel forward into bottom position and angle upward as far as possible. Lock wheel in position with lever.
- Gear selector lever in neutral.
Removing Battery And Engine Intake Components
Remove:
- battery
- air cleaner (ACL) housing and intake.
- turbocharger (TC) control valve from air cleaner (ACL) housing. (Only cars with turbocharged engines)
- battery shelf
- air cleaner (ACL) housing bracket mounting screws. (Only cars with turbocharged engines)
- Remove charge air pipe clamp and hose from pipe.
- Remove intake manifold between air cleaner (ACL) and turbocharger (TC).
Removing Transmission Components
Remove:
- selector cables from bracket and levers.
- outer transmission lever by knocking out split pin.
- back-up (reversing) light switch connector.
Only Cars With Turbocharged Engines:
- Remove throttle pulley cover.
Remove:
- intake pipe to throttle body. Pull pipe to one side with a tie strap so that it is free of the throttle body (TB).
- upper oil cooler hose to the engine oil cooler.
Removing Clutch Slave Cylinder
- Remove clutch slave cylinder from transmission Remove circlip.
Caution: Ensure that boot stays in place on cylinder.
Remove:
- ground lead from transmission
- Engine cable harness clamp(s).
Removing Engine - Transmission Screw
- Undo rear engine pad/splash guard nut a few turns.
- Remove screws (5) holding starter motor/transmission.
- Lift engine coolant expansion tank from its mounting and put to one side.
Only cars with EGR:
- Disconnect hoses from control valve (A)
Removing torque rod/torque control arm screw
- Remove torque rod/torque control arm screw at engine.
- Disconnect ground strip from firewall.
- Install lifting fork 999 5534 on torque rod-engine.
Installing Supports And Lifting Beam
Install:
- supports 999 5033 on fender edges.
- lifting beam 999 5008 on supports. Locate the beam directly above the eye on the lifting fork.
- lifting hook 999 5480. Raise hook approx. 5 mm (0.196") to relieve load on engine pads.
- Note the measurement between lifting beam and spark plug cover.
Removing Front Wheel And ABS Sensor
Remove:
- front wheels
- ABS sensor from stub axle (left-hand side).
Caution: Do not separate the connector halves.
- Remove brake pipes and ABS wiring brackets (both sides). Unhook the brackets and let them hang loose.
Removing engine mounting
- Remove rear engine mounting from transmission and sub-frame.
Removing Plastic Nuts And Drive Shaft Nut
Remove:
- the front fender liner plastic nuts on both sides and the two Torx screws on the left-hand side (early version).
- left drive shaft nut. Knock out split pin (early version). Install counterhold 999 5461(4 wheel studs) or 999 5540. Remove nut.
Disconnect Drive Shaft End From Hub
- Knock in end of drive shaft approx. 10-15 mm (0.393"- 0.590") into the hub. Use a rubber or copper mallet.
Removing Covers
Remove:
- front splash guard.
- splash guard under engine.
Disconnect Control Arm/ball Joint From Stub Axle (Both Sides)
- Install protective sockets 999 5562 on ball joints (both sides).
- Disconnect and unhook control arms from anti-roll bar (both sides).
Removing Cable Conduit From Sub-frame
- Remove cable conduit mounting screw and unhook from the sub-frame.
- Remove the EVAP canister with its hoses from the sub-frame.
- Cut tie straps for hoses and hang EVAP canister in car body.
Loosen exhaust pipe clamp behind the three-way catalytic converter (TWC).
Removing Screws To Brackets And Torque Rod Mounting
Remove:
- oil pipe bracket screws.
- two screws securing torque rod mounting support on transmission.
Drain Transmission Oil
Caution : Only If the transmission or oil is to be replaced. Tighten plug to 36 Nm (25.8 ft.lb.).
On Right-hand Drive Cars Only
- Remove crash guard above the steering gear. (2 screws.)
Disconnecting Drive Shaft
- Disconnect right drive shaft.
- Remove bearing cap.
- Pull out inner section of drive shaft, at the same time fold out spring strut.
Caution: Take care not to damage the seal in the transmission.
- Install plug 999 5656.
- Let the drive shaft rest on the sub-frame and oil pipes.
Removing Engine Pad Screws
- Remove front engine mount/sub-frame screw Undo the screw on the engine mount/steering gear approx. one turn.
- Remove steering gear mounting nuts in the sub-frame (5).
- On right-hand drive cars only: Remove nut (A) for crash guard sub-frame.
Removing sub-frame
- Remove Sub-frame From Car.
- Position mobile jack 998 5972 lightly, to support the left-hand side of the sub-frame.
- Remove left and right sub-frame support bracket screws. Unscrew the two sub-frame mounting - car body screws on the right-hand side max 15 mm (0.590") (7 turns). Remove screws on left-hand side.
On Right-hand Drive Cars Only
- Lower sub-frame approx. 100 mm (3.93") Ensure that steering gear screws (five) and crash guard screw are clear of frame.
- Remove left-hand side anti-roll bar bearing cap screws. Undo screws on right-hand side until they are held by a short section of thread.
- Secure the anti-roll bar to the steering gear as illustrated. eye on the lifting fork.
- lifting hook 999 5480. Raise hook approx. 5 mm (0.196") to relieve load on engine pads.
Lowering Sub-frame
- Lower Sub-frame.
- Remove Mobile Jack.
Caution: Check that the steering gear screws are tree of the sub-frame. Ensure that the control arm is free of the right drive shaft boot.
Remove Mobile Jack
- Let the sub-frame hang in the right-hand side screws.
Hanging Up Steering Gear
- Hang steering gear on the left-hand side with hook 999 5045 in the hole on the frame member flange.
- Remove the engine pad - steering gear screw and the nut on top of the engine pad. Remove engine pad.
Caution: Ensure that the steering gear hangs securely on the hook so that the lower steering shaft does not slide out of the steering column.
Remove Cable Ties, Connectors, Splash Guard And Mounting On Transmission
- Tape end of drive shaft to oil pipes.
Remove:
- cable clamps for the heated oxygen sensor (HO2S) cable from engine cover.
- vehicle speed sensor (VSS) connector and cable.
Remove:
- cover at rear engine mounting.
- rear mounting from transmission.
Removing Left Drive Shaft
- Remove left drive shaft.
- Turn and fold out spring strut. Knock out the end of the drive shaft with a rubber copper mallet and pull the end of the drive shaft out of the hub.
- Remove drive shaft from transmission. Use jimmy bar 999 5462 between transmission and inside of drive shaft.
Caution : Take care not to damage drive shaft seal and boots.
- Install plug 999 5488 in transmission. Clean traces of metal adhesive from the splined joint (hub - drive shaft).
Lowering engine and transmission
- Lower engine and transmission. Use lifting hook 999 5460. Lower until the distance between the lifting beam and spark plug cover is approx. 320 mm (12.29).
Caution: If the engine is lowered too much, the exhaust pipe can press the steering gear down.
Caution: Ensure that cables and hoses are not pinched or stretched and that the engine dipstick is free from the fan.
Installing Universal Tool And Transmission Fixture
- Install universal tool 999 5972 and transmission fixture 999 5463 on the mobile jack.
- Install transmission fixture in transmission with torque rod mounting screws.
- At the same time install support plate (marked 999 5463) on the fixture.
- Raise mobile jack into contact.
- Lowering sub-frame.
Caution: Ensure that cables and hoses are not pinched or stretched and that the engine dipstick is free from the fan.
Removing screws
- Remove the rest of the screws between transmission and engine (7).
Removing Transmission
- Remove Transmission.
- Pull transmission straight out from engine.
Caution: Ensure that transmission comes straight out from engine to avoid stresses on the clutch driven plate center.
- Lower mobile jack and pull off transmission.