Side Cover Transmission, Removing
Side cover transmission, removing
Special tools:
998 5972 Jack 998 5972 Jack
999 5085 Socket 999 5085 Socket
999 5460 Lifting hook 999 5460 Lifting Hook
999 5462 Jimmy tool 999 5462 Jimmy Tool
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 7018 Lifting lug 999 7018 Lifting Lug
999 7062 Separator 999 7062 Separator
999 7070 Mounting 999 7070 Mounting
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 is always correct.
Warning! Avoid skin contact with the transmission fluid.
Removal
Disconnecting the battery lead
Remove the battery lead. See Battery, disconnecting Battery Disconnecting.
Removing engine compartment components
Remove:
- the engine stabilizer brace between the suspension turrets and the engine
- the air cleaner (ACL) housing assembly with the intake pipe.
Unhook the turbocharger (TC) control valve from the air cleaner (ACL) housing. Pull the air cleaner (ACL) housing out of its mountings.
Draining oil
Use an oil suction unit.
Remove the dip stick. Ensure that the suction pipe reaches down into the transmission.
Extract all the fluid, approximately 6 liters.
Removing the coolant hose from the passenger compartment heater
Clamp the hoses with hose clips.
Place some 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.
Disconnecting the charge air pipe
Detach the charge air pipe from the charge air cooler (CAC).
Carefully heat around the pipe at the charge air cooler (CAC). Use a hot air gun. Loosen and remove the pipe.
Removing the connector from the transmission
Remove:
- the screw for the clamp holding the positive cable on the engine
- the connector from the transmission (press the connector together). Pull it from the transmission.
Installing the lifting beams and lifting hooks on the engine lifting lugs
Note! The front lifting beam must be equipped with fixture kit 999 7070 Mounting 999 7070 Mounting as illustrated.
Position lifting beams 999 5716 Reading off tool 999 5716 Reading Off Tool on the wheel arch and directly above the engine lifting eyelets on the left and right-hand sides.
Connect the lifting hooks 999 5460 Lifting hook 999 5460 Lifting Hook on the engine lifting lugs.
On the right-hand side of the engine, the hook must have a clearance of 10 mm.
On the left-hand side of the engine, lifting lug 999 7018 Lifting lug 999 7018 Lifting Lug must be used. Connect the tool to the 2 screws at the rear edge of the engine together with lifting hook 999 5460 Lifting hook 999 5460 Lifting Hook.
Tighten to light contact on the left hand side.
Removing the lower steering shaft from the steering shaft joint
Detach the boot from the firewall and slide it up on the steering shaft.
Turn the steering wheel so that the screw for the steering shaft joint is accessible but with the wheels as straight forward as possible.
Remove the ignition key. Do not turn the steering wheel now.
Remove the screw from the steering shaft joint and slide up the lower steering shaft.
Raise the car.
Removing both the front wheels
Remove:
- both the front wheels
- the front protective panel. See Sub-frame front, replacing Service and Repair
- the splash guard under the engine.
Removing components from the sub-frame
Remove 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
Slacken off the 2 screws in the center bearing/member for the propeller shaft
Remove:
- the screws for the support for the center bearing. Let the propeller shaft rest against the exhaust pipe
- one of the screws and slacken off the other for the rear member. Turn the member to the side so that the exhaust pipe is exposed.
Removing the front cross member
Remove:
- the clamp for the heated oxygen sensors (HO2S) from the member
- the member. Remove the brake pipe from the mountings in the member
- the connector for the heated oxygen sensors (HO2S) in the sub-frame
- the rubber mountings from the exhaust pipe and the mounting on the sub-frame.
Removing screws and nuts from the engine pad and engine stabilizer brace
Remove:
- the screws for the front and rear engine pads
- the screws for the engine stabilizer brace.
Detaching the power steering line
Remove:
- the screw for the clamp for the power steering line at the front edge of the top of the sub-frame. The screw can be accessed from the front if the cable duct is lifted up
- the screw for the clamp for the power steering line on the right-hand side at the rear edge of the frame.
Unhook the servo and the evaporator lines from the holders on the right-hand side of the sub-frame.
For cars with fuel powered parking heaters
Unhook the fuel line from the holders.
Removing front suspension components on both sides
Remove:
- the soundproofing over the drive shaft (applies to certain versions)
- the screw for the drive shaft. Counterhold using a screwdriver in the brake disc vents. Tap in the end of the drive shaft approximately 20 mm into the wheel hub
- the link from the anti-roll bar. Counterhold using a Torx wrench in the ball joint pinion to prevent the boot from turning
- the nut for the ball joint / link arm. Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut
- the nut for the tie rod from the wheel spindle.
Note! Before detaching the tie rod, measure and note the distance as illustrated.
Disconnecting the ball joint pinion from the control arm (both sides)
Use tool 999 7062 Separator 999 7062 Separator.
Install cap nut 999 7062 Separator 999 7062 Separator on the ball joint pinion. Tighten the nut against the control arm. Then slacken off 1 to 2 turns so that there is clearance between the cap nut and the control arm.
Position puller 999 7062 Separator 999 7062 Separator on the control arm and detach the ball joint from the control arm.
Remove the tools.
Unhooks the control arm from the ball joint pinion (both sides)
Use lifting lug 999 5085 Socket 999 5085 Socket and a longer jimmy bar or the handle of jimmy bar 999 5462 Jimmy tool 999 5462 Jimmy Tool.
Position the lifting lug hook in the cast countersink on the control arm. Position a jimmy bar or handle of the jimmy bar through the lug on the hook and against the control arm as illustrated.
Press the control arm down and slide the wheel spindle to one side while installing protective socket 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket on the ball joint pinion. Hold it in place with the nut for the ball joint.
Removing the drive shaft from the wheel hub (both sides)
Hold the control arm as above to facilitate removal of the drive shaft joint from the hub.
Release the control arm to the rest position.
Removing the drive shaft from the transmission (left-hand side)
Use counterhold 999 5462 Jimmy tool 999 5462 Jimmy Tool modified according to the Workshop Guide Bulletin.
Do not damage the drive shaft seal when removing the end of the drive shaft from the transmission.
Remove the drive shaft.
Hold the spring struts back on both side using a tensioning strap to give more space.
Removing the fender liner and support plate
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 damage the front fender.
Removing the screws from the sub-frame support plates (both sides)
Remove the screws from the sub-frame support plates (both sides).
Position mobile jack 998 5972 JACK 998 5972 Jack with universal plate 999 5972 FIXTURE 999 5972 Fixture , so that the plate is in light contact 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.
Lowering the sub-frame
Position the mobile jack lightly applied under the left side of the sub-frame. Remove the sub-frame screws.
Note! Ensure the following when lowering the sub-frame:
- the steering shaft joint on the steering gear runs freely in the bodywork grommet
- that the brake pipe does not catch in the bracket for the exhaust pipe mounting.
Remove the mobile jack and let the frame hang loose.
Removing the oil pipe from the transmission
Note! Plug the oil pipes so that no dirt gets in.
Remove the nuts from the brackets for the oil pipes.
Remove the connection nuts from the pipes (counterhold at the connections). Pull out the oil pipes.
Move the oil pipes to one side.
Lowering the engine and transmission
Lower:
- the engine and transmission on the left-hand side. Ensure that no cables and hoses are trapped or stretched while lowering
- as much as the lifting hook allows, check through the hole in the lifting hook to see when the stop becomes visible.
Preparations for removal of the transmission side cover
Remove the gear selector cable from its clips on the side member.
Blow clean thoroughly around the cover.
Collect the oil spill when the side cover has been removed.
Remove the nut for the clamp and bracket holding the wiring. Cut off the tie straps holding the cable harness above the bracket. Move the wiring to one side. Remove the screw from the bracket. Unhook the bracket.
Remove all the screws from the side cover. Note the location of the different types of screws.
Removing the side cover
Pull out the side cover slightly from the transmission. Angle out the cover at the front on the left side quite a lot.
Pull the cover backwards to the steering gear. Pull out the cover at the bottom edge so that the upper section passes the side member. Keep the seal between the side cover and the transmission.