Transmission, Removing
Transmission, removing
Special tools:
998 5972 JACK 998 5972 Jack
999 5460 Lifting hook 999 5460 Lifting Hook
999 5462 Jimmy tool 999 5462 Jimmy Tool
999 5463 FIXTURE 999 5463 Fixture
999 5488 PLUGS 999 5488 Plugs
999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket
999 5716 Reading off tool 999 5716 Reading Off Tool
999 5972 FIXTURE 999 5972 Fixture
999 7057 Counterhold 999 7057 Counterhold
999 7076 Lever 999 7076 Lever
999 7077 Jimmy bar 999 7077 Jimmy Bar
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.
Preparations
Disconnecting the battery lead
Disconnect the battery negative lead. See: Battery, disconnecting Battery Disconnecting.
Removal
Removing engine compartment components
Remove:
- the engine stabilizer brace between the suspension turrets and the engine
- the cover on the side of the air cleaner (ACL) housing
- the fresh air intake hose
- the air filter housing complete, unhook the control valve from the air filter housing.
Removing components from the transmission
Plug the clutch cable hose. Use a hose clip.
Remove:
- the clutch hose from the junctions. Seal the opening to prevent intrusion of dirt. Wipe up any spillage
- the cable harness clamps
- the ground lead from the transmission and the sub-frame
- the bracket for the air cleaner (ACL) housing from the transmission.
Removing the gear selector cables from the transmission
Note! When working with the mechanical cables ensure that the cable sleeves do not crack or break.
Use jimmy bar 999 7077 Jimmy bar 999 7077 Jimmy Bar.
Remove:
- the gear selector cables from the levers
- the mechanical cables from the bracket by moving the sleeves back on the cables. Tie up the cables
- the connector for the back-up lamp switch
- the bracket with the connectors for the heated oxygen sensors (HO2S)
- the bracket for the coolant hose(s)
- the clamp for the cable harness at the rear of the engine.
Tie up the cable harness and the coolant hose(s).
Remove:
- the 3 screws for the transmission / engine
- the 2 screws for the starter motor.
Removing the coolant hose from the passenger compartment heater
Clamp the hoses with hose clips.
Place paper under the inner hose connection to collect any spilled coolant.
Turn the quick-release connector (the inner of the 2 hoses) slightly in the direction of the arrow so that the lock opens. At the same time, pull the coolant hose straight out of the coolant pipe.
Note! Tie the hose up to the engine so that it does not fall down and trap the hose connector against the firewall during installation.
Installing the lifting beam and lifting hook on the engine lifting eyelet
Position the lifting beams 999 5716 Reading off tool 999 5716 Reading Off Tool on the wheel arch and straight above the engine's lifting lug on the left and right hand-sides. Connect the lifting hooks 999 5460 Lifting hook 999 5460 Lifting Hook on the right-hand side of the engine with a clearance of approximately 5-10 mm. Lightly tighten on the left-hand side.
Position the wheels in the straight ahead position. Remove the ignition key. Activate the steering wheel column lock.
Raise the car.
Removing the air baffle and splash guard under the engine
Remove:
- both the front wheels
- the screws for the splash guard under the engine
- the screws for the air baffle. Press in the catches holding the air baffle. Remove the air baffle.
Removing the screw for the cable duct
Unhook the cable duct from the sub-frame.
For cars with fuel powered parking heaters:
Remove the 2 screws for the heater.
Unhook the heater from the mounting. Leaving it hanging in its upper mounting.
Detach the fuel line for the heater from the holders on the sub-frame.
Removing the cross members from the body
Remove:
- the clamp for the heated oxygen sensor (HO2S) cable and the brake pipe from the holders on the front member
- the front member
- the middle member. Loosen the screws on one side and then remove them completely on the other side.
Removing screws and nuts from the engine pad and engine stabilizer brace
Remove:
- the screw for the front/rear engine pad
- the screws for the torque rod.
Measuring the position of the tie rod in the steering gear
On one side, measure the length of the track rod in relation to the steering gear housing. Note the measurement.
Exposing the steering shaft joint
Remove the screw, 1, to the joint between the steering gear and the steering wheel shaft.
Press the joint up from the steering shaft.
Detach the cable to step motor/solenoid.
Removing front suspension components (both sides)
Detach the ABS cable from the bracket in the spring strut on the left-hand side.
Remove:
- the screw for the drive shaft using a screwdriver in the brake disc vents
- the nut for the ball joint / link arm. Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut.
Note! Counterhold at the ball joint pinion using a Torx TX 40 when removing the nut. This is so that the ball joint boot does not turn.
Remove (on left side):
- the link from the anti-roll bar
- the tie rod.
Preparations when removing transmission
Remove the 2 nuts from the fender liner and the support plate. Angle out and tie up the fender liner to the lifting beam. Use a retaining strap.
Note! Do not forget to protect the front fender.
Draining transmission fluid
Position a container underneath the transmission.
Remove the drain plug (1). Drain the oil.
Reinstall the plug together with a new gasket. Tighten. See applicable specifications.
Preparations for lowering the sub-frame
Unhook the control arms from the ball joints on both sides. Use: 999 7076 Lever 999 7076 Lever.
Note! Do not trap the ball joint boot.
Install: 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket.
Hold the sleeve in place using the nut for the ball joint.
Fold out the spring strut. Remove the drive shafts from the wheel hub. Do not damage the boots.
Hold the spring struts to one side to obtain more space when removing the drive shafts. Use a retaining strap.
Keep the seal on the outer constant velocity joint housing if it falls off.
Remove the screws from the sub-frame support plates (both sides).
Lightly position 998 5972 JACK 998 5972 Jack together with 999 5972 FIXTURE 999 5972 Fixture under the right-hand side of the sub-frame.
Slacken off the screws for the sub-frame on the right hand side. Ensure that the nuts are still secured by at least 5 threads.
Remove the jack.
Removing the right drive shaft
Remove:
- the screws for the drive shaft's support bearing cap
- the support bearing cap
- the drive shaft by pulling it straight out of the transmission. On cars with four-wheel drive, the drive shaft runs through the bevel gear.
Removing the collision protection system over the steering gear
Note! Applies only to right-hand drive cars.
Remove the 2 screws for the collision protection system. Leave the collision protection system in place on the steering gear.
Lowering the sub-frame
Position the mobile jack lightly applied under the left side of the sub-frame.
Remove the sub-frame screws.
Lower the sub-frame.
Note! When lowering, make sure that hoses and cables are in the clear and are not stretched. Remove the mobile jack and let the frame hang freely.
Removing the left-hand drive shaft
Fold out the spring strut. Remove the drive shaft from the wheel hub.
Hold the spring strut to one side using a retaining strap to obtain more space when removing the transmission.
Remove the drive shaft from the transmission. Use: 999 5462 Jimmy tool 999 5462 Jimmy Tool.
Install: 999 5488 PLUGS 999 5488 Plugs for the transmission.
Removing bevel gear
Remove the angle gear screws, 5. Pull the angle gear straight out from the gearbox.
Hang the bevel gear from, e.g., an oil pipe for the turbocharger or similar.
Removing the rear engine mounting
Remove:
- the screw for the engine pad / steering gear
- the screws, 3 pcs.
- the mounting and the engine pad.
Lowering engine and transmission
Lower the car.
Lower the engine and transmission on the left-hand side. Use the hook.
Note! Check that no hoses or cables are being stretched or trapped when the engine is lowered.
Lower the engine to the lifting hook stop. This can be seen in the hole in the upper section of the hook as arrowed.
Raise the car.
Installing the fixture on the mobile jack and transmission
Install: 999 5463 FIXTURE 999 5463 Fixture to: 999 5972 FIXTURE 999 5972 Fixture. Position the unit on: 998 5972 JACK 998 5972 Jack.
Align the fixture on the transmission using the 2 screws for the engine stabilizer brace. At the same time align support plate 5463-1 with the fixture and the transmission. Tighten the screws.
Apply the mobile jack lightly against the transmission.
Removing the engine and transmission screws
Remove the remaining 7 screws for the transmission and engine.
Removing the transmission
Note! Ensure that the transmission is removed straight out in relation to the engine so that no damage occurs between the primary shaft for the transmission and the center of the clutch driven plate.
Lower the transmission when it is free from the clutch.
Remove the transmission.