Replacing Transmission
Replacing the transmission
Special tools:
115 8147 TORQUE SOCKET 1/2" 19 MM 115 8147 Torque Socket 1/2" 19 mm
951 2661 Replaced by 9512834 951 2661 Replaced by 9512834
998 5972 JACK 998 5972 Jack
999 5006 LIFTING BAR 999 5006 Lifting Bar
999 5396 PUNCH 999 5396 Punch
999 5460 Lifting hook 999 5460 Lifting Hook
999 5463 FIXTURE 999 5463 Fixture
999 5488 PLUGS 999 5488 Plugs
999 5633 Replaced by 9995681 999 5633 Replaced By 9995681
999 5972 FIXTURE 999 5972 Fixture
999 5681 Jimmy bar 999 5681 Jimmy Bar
999 5682 Tensioner band 999 5682 Tensioner Band
Removing
Introduction
Caution! Cleanliness is extremely important when working on automatic transmissions.Ensure that the workplace is free of dirt and dust. Always use clean containers.Clean around the connectors, oil filler pipe and draining plug.
Warning! Avoid skin contact with transmission fluid.
Remove the engine compartment components
Remove:
- The panel in front of the battery
- The battery
- The air cleaner (ACL) housing assembly, see Replacing the air cleaner (ACL) Replacing Air Cleaner (ACL)
- The battery shelf.
Disconnect the hose from the charge air cooler (CAC) at the intake manifold
Slacken off the clamp between the turbocharger (TC), the charge air pipe and the mounting from the pipe in the engine mounting lug.
Remove the clamp from the charge air cooler (CAC) hose.
Remove the charge air pipe.
Disconnecting the transmission connectors
Cut off the cable harness tie straps.
Disconnect the connector bracket from the mounting on the transmission.
Separate the connector halves.
Removing the screws joining the transmission, the engine and the starter motor
Remove:
- The pipe nut for the oil cooler.
Remove:
- The dipstick and plug opening
- The screws between the transmission and engine and the transmission and starter motor (five screws).
Remove the Poly V-belt
Only block the Poly V-belt.
Installing hoist
Install:
- Lifting beam 999 5006 LIFTING BAR 999 5006 Lifting Bar
- Lifting hook 999 5460 Lifting hook 999 5460 Lifting Hook.
Locate the lifting beam directly above the lifting eyelet on the engine
Raise the lifting hook a little.
Removing the front wheel and splash guards
Remove:
- The front wheels
- The front and rear splash guards under the engine
- The splash guard in wheel arch (left-hand side).
Removing the components on the left and right-hand sides:
Remove:
- The brake hose from spring strut mounting
- The ABS cable from mountings in the wheel arch and on the spring strut.
Remove the nuts for the spring strut-stub axle. Leave the screws in position.
Disconnecting the drive shaft, left-hand side
Remove (on the left-hand side):
- The drive shaft from the transmission enough to free the circlip from the [1][2]differential drive. Use tool 999 5633 Replaced by 9995681 999 5633 Replaced By 9995681.
Remove the hose and the clamp
Remove:
- the hose between the pipe and the charge air cooler (CAC)
- the pipe clamp and the hose from bracket on the transmission.
Removing, left-hand side:
Ensure that the steering wheel is in its neutral position.
Remove the stub axle from the spring strut.
Fold out the stub axle and pull the drive shaft out from transmission.
Caution! Take care not to damage the sealing ring in the transmission.
Secure the stub axle using one of the screws.
Secure the drive shaft using a tie strap. Protect the end of the drive shaft from dirt.
Knock out the right drive shaft enough to free the circlip from the [1][2]differential drive. Use tool 999 5396 PUNCH 999 5396 Punch. The tool has been modified according to Workshop Guide.
Install plug 999 5488 PLUGS 999 5488 Plugs.
Remove the longitudinal beam
Remove:
- the heat shield for the engine rubber
- the nuts from the engine rubbers
- the front and rear bolts
- the two bolts from the engine rubbers. Remove the longitudinal beam from the car.
Remove the cross stay member
- Remove the bolts
- Remove the stay.
Removing on the right-hand side
Pull the drive shaft out of the transmission.
Remove the stub axle from the spring strut. Turn the stub axle (steering left) while pulling the drive shaft out of the transmission.
Caution! Take care not to damage the sealing ring in the transmission.
Let the drive shaft rest against the front axle member.
Install plug 999 5488 PLUGS 999 5488 Plugs.
Tie up the stub axle so as not to stretch the brake hose.
Remove:
- The front and rear transmission brackets
- The screw on the exhaust pipe mounting.
Remove the AC compressor
- Remove the bracket for the AC pipe from the front engine bracket
- Remove the compressor and hang it up,
Only block the compressor.
Disconnecting the oil pipes
Disconnect the oil pipe connections from the transmission. Push the connections to one side.
Ensure that no dirt gets into the transmission and hoses.
Seal all the openings using plastic plugs.
Note! Do not remove the hoses from the pipes.
Removing the torque converter screws
(6 screws). Use Torx socket TX50.
Open the hatch in the right fender liner. Turn the crankshaft using a socket.
Lowering the engine
Remove the mounting screws for the upper transmission.
Lower the engine until the gap between the lifting beam and lifting eyelet is approx. 170 mm. See illustration.
Note! Ensure that the cables and hoses are not trapped or stretched.
Connecting the fixture
Install universal tool 999 5972 FIXTURE 999 5972 Fixture and transmission fixture 999 5463 FIXTURE 999 5463 Fixture on the mobile jack.
Install the transmission fixture on the transmission using two M10x35 screws.
At the same time install bearing plate (number 9995463-1) on the fixture. The bearing plate has been modified according to the Workshop Guide.
Bring the mobile jack lightly into contact.
Removing the engine-transmission screws
Remove the remaining screws between the engine and transmission (six screws).
Removing the transmission
Carefully remove the transmission from the engine.
Ensure that the torque converter is removed with the transmission and does not slide off the stator shaft. Use the hole in torque converter cover to press the torque converter.
Turn the transmission a little and remove it.
Caution! Take care not to damage the ring on the carrier plate for the flywheel sensor.
Cleaning and inspection
Checking the transmission
Inspect the transmission and electrical connections.
Carefully clean around the oil pipe connections.
Check that torque converter cover mating surfaces are clean.
When replacing the transmission:
- Transfer the connector bracket to the new transmission
- Install the torque converter lock plate on the old transmission.
Checking the carrier plate
Check:
- That the carrier plate is not damaged or cracked
- That the mating surfaces between the transmission and engine are clean
- That the guide bushings are intact and in place
- That the torque converter bushing in the crankshaft is intact.
Flushing the oil cooler
Place a container under the oil cooler return line.
Connect a lubricant gun and hose to the oil cooler pressure pipe.
Flush the oil cooler with ATF oil.
Checking the position of the torque converter
Ensure that the torque converter is as far in towards the transmission as it will go.
Check with a ruler. The gap between the cover and mounting lugs should be approx. 10.5 mm.
Apply a light coating of grease to the guide studs for the torque converter guide studs. Apply a light coating of grease in the holes for the guide bushings on the torque converter cover.
Installing
Note! In case of a new transmission, transfer all the necessary parts.
Installing the transmission
Use a mobile jack and transmission fixture to adjust the height and angle.
Locate the transmission on the engine.
Caution! Take care not to damage the ring on the carrier plate for the flywheel sensor.
Reinstall the screws (six screws). Tighten alternately to light pressure. Then tighten alternately.
Tightening torque: 50 Nm.
Caution! When tightening the screws carefully check that the guide bushings locate correctly in their guide holes and that the torque converter cover is in contact with the engine before tightening.
Remove the fixture and mobile jack from the transmission.
Lifting the engine and transmission
Lower the car.
Raise the engine and transmission
Locate and install the upper transmission mounting (3 screws).
Tighten the screws.
Tightening torque: 50 Nm.
Remove the lifting hook and lifting beam.
Installing the transmission-engine screws
Install:
- The other transmission-starter motor screws (two screws)
Tightening torque: 50 Nm
- The other transmission-engine screws (three screws).
Tightening torque: 50 Nm.
Note! The two screws holding the bracket for the engine coolant hose.
- Clamp the engine coolant hose to the bracket.
Installing the torque converter screws
Caution! Use new screws, Torx TX50.
Locate the torque converter on the carrier plate by turning engine using the crankshaft pulley nut (accessible through the fender liner hatch).
Install all screws loosely (six screws). Tighten the screws until the heads are in contact with the carrier plate.
Then tighten to 35 Nm. Socket Torx TX 50.
Caution! Remove the socket from the crankshaft when the work is complete.
Installing the front and rear brackets
Check the position of the drive shaft. Check carefully that it is below the rear bracket when installing.
Install:
- The front and rear mounting brackets to transmission housing.
Tightening torques:
- rear 40 Nm
- front 50 Nm.
- Screw on the exhaust pipe mounting.
Install the AC compressor
- Position the compressor, see
- Connect the wiring to the AC compressor
- Position the AC hose with clamp. Tighten to the front engine bracket.
Installing left/right drive shafts
Install the drive shafts in the [1][2]differential housing.
At the same time locate the stub axles on the spring strut. Install the screws loosely. The nuts will be installed later.
Caution! Take care not to damage the boots and the sealing rings.Press in the drive shafts properly.
Checking the drive shafts
Check that the drive shafts are locked into place in the [1][2]differential drive by carefully pulling at the drive shaft constant velocity joints. The drive shaft should stay in position.
Install the hose to the charge air cooler (CAC)/charge air pipe
At the same time locate the upper clamp in the transmission mounting.
Install the spacer sleeve and the nut on the clamp screw.
Tighten the hose clamps and the nut.
Installing the longitudinal beam
Install the longitudinal beam and push two bolts (B) into the engine rubbers. Tighten the two bolts. Torque setting 69 Nm.
Note! Position the rubbers in the correct position (see illustration). The rear and front of the center member must be in similar positions.
Slacken off the front-mounting bolster bolt (A). First tighten the rear-mounting bolster bolt (torque setting 55 Nm), then tighten the front-mounting bolt again (torque setting 55 Nm).
Install the heatshield.
Install the stay for the front cross member
Installing the oil pipes
Install the lower pipe. Use a new O-ring, tighten to 30 Nm.
Install the upper pipe (return line) with its mounting in the control system cover.
Install the connector loosely. The pipe cap nut is tightened later.
Tightening the stub axle/installing the ABS and brake lines
Install:
- New lock nuts stub axle-spring strut.
Tightening torque: 90 Nm
- The ABS line on the wheel arch and spring strut
- The brake hose with the mounting clip on the spring strut.
Installing the splash guards and wheels
Install:
- The splash guard in the left wheel arch
- The splash guards under the transmission/engine
- The wheels.
See Installing wheels, AW50-42 Installing Wheels.
Installing, continued
Lower the car.
Tighten the return oil pipe cap nut on the control system cover.
Install:
- The oil dipstick pipe with a new O-ring.
Tightening torque: 25 Nm
- The bracket with the transmission connectors. Connect all the connectors. Secure the wiring from the control system in the bracket
- The ground lead to the transmission (clean).
Installing the gear selector cable
Adjust the gear selector cable. Install on the transmission. See Adjusting the transmission cable Adjusting The Transmission Cable.
Install the charge air pipe to the hose from the turbocharger (TC).
Do not tighten any clamps yet.
Install and tighten the hose clamp and the charge air pipe securing the clamp
Install:
- the hose to the intake manifold
- the battery lead to the mounting on the transmission
- the ground lead to the transmission. Torque to 40 Nm.
Install the Poly V-belt
Install the engine compartment components
Install:
- the battery shelf
- the air cleaner (ACL) housing assembly, see Replacing the air cleaner (ACL) Replacing Air Cleaner (ACL)
- the battery
- the panel in front of the battery.
Finishing
Checking the transmission oil level
Caution! Only automatic transmission fluid which meets both Dexron III alternatively Ford Mercon standards may be used.
Note! When the oil and transmission are cold and the engine is off the correct oil level is only a few mm up the dipstick.
Check oil level when the transmission and oil are hot
Note! Check the oil level when the oil temperature is approx. +80°C.
The gear selector should be in position P and the engine idling.
See Checking oil level, AW50-42 Checking Oil Level.
Checking the diagnostic trouble codes (DTCs)
Check, remedy and erase diagnostic trouble codes (DTCs).
Test driving
Test drive with the mode selector in all three positions (E, W, S)
Checking the oil level
See Checking the transmission oil level. See also Checking oil level, AW50-42 Checking Oil Level.
Checking diagnostic trouble codes (DTCs) after test driving the car
Check that no diagnostic trouble codes (DTCs) have been stored. Remedy and erase diagnostic trouble codes (DTCs).
Returning the transmission. (Only when replacing entire transmission assembly)
Returning the old transmission unit
In order to accurately analyze the transmission fault, information is required about all symptoms which have caused the unit to be replaced. This information should be entered on the test drive form "Diagnosis and check list" which is available.
Ensure that the form has been filled out accurately
Clearly enter all the fault symptoms under the heading "Customer Complaints". Fill in the results after test driving the car.
Place the completed form in a plastic folder behind the torque converter so that it will not fall out.
The different sections of the form are to be used as follows:
- The white copy goes with the transmission
- The yellow copy is sent to the importer
- The pink copy is kept by the issuing party.