Replacing The Transmission
Replacing the transmission
Special tools:
999 5463 FIXTURE 999 5463 Fixture
Removal
Introduction
Caution! Cleanliness it important when working with the transmission.Make sure that the work area is free of dirt and dust. Always use clean receptacles.Clean around connections, filler pipes and drain plug.
Warning! Avoid skin contact with the transmission fluid.
Removing engine compartment components
Remove:
- the engine casing
- the battery
- the air cleaner (ACL) housing
- the battery shelf.
Note when removing the battery cable - see Note when disconnecting and connecting the battery lead Battery Disconnecting.
Detaching engine compartment components
Remove:
- the fresh air hose with connections and connectors from the induction pipe.
Move the hose aside and place it it on the fuse box.
- the shift cable from the transmission
- the ground cable from the transmission
- the mounting of the wiring
- the engine speed sensor.
Detaching transmission connectors
Part the connectors.
Installing the lifting device
Install:
- lifting brace 999 5006 LIFTING BAR 999 5006 Lifting Bar
- lifting hook 999 5460 Lifting hook 999 5460 Lifting Hook.
Position the lifting brace right above the engine lifting eye.
Tighten the lifting hook slightly.
Removing the heat deflector plate and member
Remove the heat deflector plate and member as described in.
(For USA only). Remove the heat deflector plate and member as described in Replacing the cross member, AW55-50/51SN Service and Repair.
Remove the engine bracket.
Detach the front engine bracket.
Detaching the left-hand side drive shaft
Detach the drive shaft as described in Drive shaft left-hand side, replace, AW55-50/51SN Drive Shaft Left-Hand Side, Replace.
Detaching the right-hand side drive shaft
Detach the drive shaft as described in Drive shaft right-hand side, replace, AW55-50/51SN Drive Shaft Right-Hand Side, Replace.
Detaching oil pipes
Drain the transmission fluid as described in Oil, changing, AW55-50/51SN Changing Oil.
Detach oil pipe connections on the transmissionand move them aside.
Detach the bracket of the upper pipe.
Detach the clamp holding the pipes together.
Make sure that no contaminants enter the transmission and hoses.
Seal all connections with plastic plugs.
Removing the screws from the torque converter
Number of screws (6). Use Torx socket TX50.
Open the hatch in the wheel arch liner on the right side and rotate the crankshaft using a socket wrench.
Connecting fixture
Fit universal tool 999 5972 FIXTURE 999 5972 Fixture and transmission fixture 999 5463 FIXTURE 999 5463 Fixture on the mobile jack.
Use 2 M10x35 screws to secure the transmission fixture to the transmission.
At the same time, fit the support plate (number 9995463-1) on the fixture. The support plate in modified as per the Tool Bulletin.
Position the mobile jack just until it makes contact.
Removing the engine, transmission and starter motor screws
Remove the screws between the transmission and engine/starter motor (5).
Removing the engine mounting
Remove:
- the 3 nuts
- the through screw
- the engine mount.
Removing the screws, engine/transmission
Remove the 7 remaining screws between the engine and transmission.
Removing the transmission
Carefully detach the transmission from the engine.
Lower the engine slightly.
Make sure that the torque converter is removed with the transmission and does not slide off the stator shaft. Use the hole in the torque converter cover to press on the torque converter.
Turn the crankshaft slightly and remove it.
Caution! Be careful not to damage the carrier plate collar for the flywheel sensor.
Cleaning and checking
Checking the transaxle
Inspect the transmission and electrical connections.
Thoroughly clean around the oil pipe connections.
Make sure that the mating surfaces on the torque converter cover are clean.
When replacing the transmission
- Transfer the connector bracket to the new transmission.
- Fit the lock plate for the torque converter on the old transmission.
Checking the carrier plate
Check:
- that the carrier plate is not damaged or cracked.
- that the transmission/engine mating surfaces are clean
- that the guide sleeves are intact and in place
- that the bushing for the torque converter in the crankshaft is free from defects.
Flushing the oil cooler
Position a container under the radiator return line.
Connect an oil suctioner with hose to the radiator delivery line.
Flush the oil cooler with ATF fluid.
Checking that the torque converter position
Ensure that the torque converter is as far in towards the transmission as possible.
Check with a ruler. The distance between the cover and retaining lugs should be about 14 mm.
Apply a light coating of grease to the torque converter guide studs and in the holes for the guide bushings on the torque converter cover.
Installation
Installing the transmission
Adjust for height and angle using the mobile jack and the transmission fixture.
Align the transmission against the engine.
Caution! Be careful not to damage the carrier plate collar for the flywheel sensor.
Fit the 6 screws. Tighten alternatingly finger-tight. Then tighten alternatingly.
Torque: 50 Nm.
Caution! When tightening the screws, check carefully that the guide bushings locate correctly in their guide holes. Check that the torque converter cover is in contact with the engine before tightening.
Lifting engine and transmission
- Raise the engine and transmission.
- Position and fasten the upper mounting to the transmission (3 screws).
- Tighten the screws.
- Torque: 50 Nm.
- Remove the lifting hook and lifting brace.
- Remove the fixture and the mobile jack from the transmission.
Installing the screws, transmission/engine
Install:
- other screws to the transmission and starter motor (2).
Tighten to 50 Nm
- other screws to the transmission and engine (3).
Tighten to 50 Nm.
Fitting the torque converter screws.
Caution! Use new screws, Torx TX50.
Fit the torque converter to the carrier plate by rotating the engine with the nut of the crankshaft pulley (accessible through the hatch in the right wheel arch liner) while turning the torque converter at the same time.
Fit all 6 screws finger-tight. Tighten the screws so that the screw heads make contact with the carrier plate.
Then tighten to 35 Nm. Torx socket TX50.
Caution! Remove the socket wrench from the crankshaft once work is complete.
Installing the front and rear brackets
Fit the front bracket in the gearcase.
Tighten to 60 Nm.
Fit the rear bracket in the gearcase.
Tighten to 60 Nm.
Installing left/right drive shafts
Install the left-hand drive shaft. See: Drive shaft left-hand side, replace, AW55-50/51SN Drive Shaft Left-Hand Side, Replace.
Install the right-hand drive shaft. See: Drive shaft right-hand side, replace, AW55-50/51SN Drive Shaft Right-Hand Side, Replace.
Installing the support member
Install the support member;
(For USA only) Install the support member; see Replacing the cross member, AW55-50/51SN Service and Repair.
Installing the oil pipes
Fit the lower pipe using a new O-ring.
Fit the upper pipe (return line) with mounting in the control system cover.
Fit the connection loosely. The bearing cap of the pipe will be tightened later.
Assemble the clamp and tighten the screw.
Installation, cont.
Tighten the bearing caps of the return oil pipe on the control system cover.
Install:
- transmission connectors
- ground cable to the transmission
- the mounting of the wiring
- the engine speed sensor.
Installing the shift cable
Install the shift cable; see Shift cable, replacing, AW55-50/51SN Removal and Replacement.
Adjusting the gear cable
Adjust the shift cable as described in Adjusting the mechanical cable for the transmission, AW55-50/51SN Adjustments.
Installing other components
Install:
- the battery shelf
- the fresh air hose with connections
- the preheating hose
- the air cleaner housing assembly
- the engine cover
- the battery.
Note when installing the battery cable - see Note when disconnecting and connecting the battery lead Battery Disconnecting.
Finishing
Checking the fluid level in the transmission
Caution! Only ATF fluid may be used, part no. 1161540-8 (1 liter container).
Note! When the fluid and transmission are cold and the engine is off, the right fluid level is only up a few mm on the dipstick.
Check the fluid level when the transmission and fluid are warm.
Note! The check should be done when the fluid temperature is about +80°C (176°F).
The gear selector should be in P and the engine should be idling.
See Checking and adjusting the oil, AW55-50/51SN Checking Oil Level.
Checking the diagnostic trouble codes (DTCs)
Check, remedy and clear any diagnostic trouble codes.
Test driving
Test drive the car with and without the program selector in W.
Checking the oil level
See Checking the fluid level in the transmission.