Complete automatic transmission: Fitting

Fig 1: Illustration For Step 1

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When fitting a new transmission, transfer the holder for the torque converter from the new transmission to the old one.

1. Turn the torque converter so that the bolt holes line up with the holes in the drive plate.

   Fit 87 92 574 HOLDER  to keep the torque converter in place while fitting.

2. Make sure the two guide sleeves are on the engine and apply anti-corrosion agent to the sleeves.

   Fit the new drive shaft seals, lubricate them before fitting.

3. Lift up the gearbox using an engine hoist and 87 92 442 LIFTING CABLE .
4. Fit Lifting tool MKM-88687 92 608 onto a pillar-type jack.
   Fig 2: Installing Lifting Tool

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5. Adjust the tool so that it centers on the lifting lug on top of the transmission casing and secure it to the transmission.
   Fig 3: Adjusting Lifting Tool

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   IMPORTANT: The pillar-type jack may tip over. Exercise care.
6. Fit Protective collar83 95 162 PROTECTIVE COLLAR, DRIVE SHAFTS  in the right-hand shaft seal in the transmission to protect the seal when the transmission is being fitted. Lubricate the seal.
   Fig 4: Illustration For Step 6

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7. Place the transmission in position.
   IMPORTANT: Push the transmission into place until approx. 20 mm remains and then remove tool 83 95 162 PROTECTIVE COLLAR, DRIVE SHAFTS .
8. Tighten the bottom bolts between the engine and the transmission.

   Tightening torque: 75 Nm (55 lbf ft) 

   V6: Tighten the bolts between the oil pan and the transmission.

   Tightening torque: 47 Nm (34 lbf ft) 

   Fig 5: Illustration For Steps 8, 10

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9. Remove the lifting beam from the transmission and move the jack out of the way. Refit the bolts in the gearbox.

   Tightening torque 24 Nm (18 lbf ft) 

10. Lower the car and fit the engine pad mounting on the gearbox.

    Tightening torque: 84 Nm (62 lbf ft) 

    Lift the unit. Do not lift higher than necessary, it will only make fitting the subframe more difficult. Fit the bolts that secure the engine pad to the body. Start with the small bolt.

    Tightening torque, bolts: 63 Nm (46 lbf ft) 

    Tightening torque, nut: 84 Nm (62 lbf ft) 

11. Fit protective collar 83 95 162 PROTECTIVE COLLAR, DRIVE SHAFTS  in the sealing ring. Lubricate the sealing ring.
    Fig 6: Illustration For Steps 11, 13

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12. Make sure that the drive shaft is clean and then align it with the tool.
    IMPORTANT: Insert all but 20 mm of the drive shaft in the transmission and then withdraw the tool before the shaft's sealing surface reaches the shaft seal.
13. Push in the rest of the shaft until the circlip clicks in.
14. Raise the car.
15. Remove tool 87 92 574 HOLDER , which is keeping the torque converter in place, and press it against the drive plate. Fit the plug.
    Fig 7: Illustration For Steps 15-17

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16. Apply threadlock, LOCTITE 242 part no 74 96 268 to the bolts that secure the torque converter to the drive plate.
    NOTE: Use the original bolts and their washers. If excessively long bolts are fitted, the torque converter will be damaged. The length of the bolts should be 10 mm, measured from the washer.
17. Fit the 6 bolts without tightening them.

    Rotate the engine with the pulley

18. Tighten them when they are all fitted in place.

    Tightening torque: 30 Nm (22 lbf ft) 

19. 4-cyl: Fit the splash plate.

    V6: Fit the plug.

20. Fit the oil cooler hoses. The hoses should be horizontal so that they do not chafe against the subframe. Use new seals greased with petroleum jelly.
    Fig 8: Illustration For Steps 20-22

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    Tightening torque: 27 Nm (20 lbf ft) 

21. Fit the bracket for the torque arm on the transmission.
22. Connect the ground cable to the bracket and to the transmission.
23. Place the subframe on the lifting trolley and raise it slightly.
    Fig 9: Illustration For Steps 24, 26

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24. Fit the power steering delivery pipe's clamps.
25. Raise the subframe and guide it into position by means of the holder's studs. At the same time, guide the following into place:

    The radiator core's studs

    The AC pipes

    Outer ball joints

26. Fit the bolts to the subframe and fit the rear support plates. Adjust the subframe so that the guide pins on the holder are aligned with the holes in the body before tightening the bolts.

    Tightening torques: 

    Subframe bolts 100 Nm (74 lbf ft) + 45 ° 

    Support plate bolts: 60 Nm (44 lbf ft) 

    NOTE: Make sure that the transmission's oil cooler hoses do not rest against the subframe.
27. Remove the lifting trolley.
28. Fit the bolts securing the outer ball joint to the steering knuckle housing.
    Fig 10: Illustration For Steps 28, 30

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29. Tighten the bolts.

    Tightening torque 60 Nm + 90 ° (44 lbf ft + 90°) 

30. Tighten the anti-roll bar link. If the wrench used to hold it is too wide to fit between the boot and the suspension strut, it must be ground narrower. Alternatively, hold the hexagonal pin with a socket.

    Tightening torque 84 Nm (62 lbf ft) 

    Tightening torque, nut with steel lock: 95 Nm (66 lbf ft) 

31. Fit the steering gear bolts and tighten them.

    Tightening torque 90 Nm (66 lbf ft) 

    Fig 11: Illustration For Steps 31, 33

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32. Remove the strap round the radiator core.
33. 4-cyl: Fit the engine oil cooler. Tighten the air filter housing.
34. Fit the rear engine cushion in place. Screw in the front bolts but do not tighten them.
35. Bolt the rear engine mounting in place.

    Tightening torque: 70 Nm (52 lbf ft) 

    Fig 12: Illustration For Steps 35-37, 39

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36. Tighten the torque arm on the subframe

    Tightening torque 26 Nm (19 lbf ft) 

37. Fit the front exhaust system.

    Tightening torque 4-cyl: 25 Nm (18.4 lbf ft) 

    Tightening torque V6: 

    to the turbo 24 Nm (18 lbf ft) 

    to the exhaust manifold 40 Nm (30 lbf ft) 

38. Run the wiring for the oxygen sensor into the engine bay.
39. Fit the covers.
40. Lower the car to the floor.
41. Remove the lifting beam.

    V6: Remove the lifting tool and its mountings from the engine.

42. Connect the oxygen sensors
43. Shake the unit to ensure there is no tension in the engine pads.

    Tighten the rear engine pad retaining nut and 3 bolts.

    Tightening torque: bolts 24 Nm (18 lbf ft) 

    Tightening torque: nut 45 Nm (33 lbf ft) 

    Fig 13: Illustration For Step 43

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44. Fit the bolts securing the transmission to the engine and tighten them.

    Tightening torque: 70 Nm (52 lbf ft) 

    V6: Screw on the cable duct to the engine and transmission.

    Fig 14: Illustration For Steps 44-47

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45. Clean and fit the dipstick tube.
46. Fit the transmission's breather hose.
47. Fit the shifting cable to the bracket on the transmission. Fit the clamp.
48. Fit the shifting cable to the selector lever in position P.
49. Check the position of the selector lever and adjust if necessary, see SELECTOR LEVER .
Fig 15: Illustration For Step 50
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50. Raise the car.

    Undo the bolt for the front torque rod and center the rubber pad in the rod. Tighten the bolt.

    Tightening torque: 47 Nm (34 lbf ft) 

    Lower the car to the floor.

51. Plug in the transmission's connectors.
    Fig 16: Illustration For Steps 52-53

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52. Fit the battery tray, battery and battery cover.
53. Fit the cover over the intake manifold.
54. Fit the grille.
55. Fit the front wheels. Tighten the bolts using a torque wrench. NOTE! the wheels must hang freely

    Tightening torque: 110 Nm (81 lbf ft) 

56. Fill with transmission fluid, Texaco Texamatic DEXRON III (7045 EU, TL1863 US), to the correct level.
57. If the gearbox has been changed and dirt is found in the oil, flushing equipment 87 91 824 FLUSHING EQUIPMENT  must be connected before the car is started.
58. Test drive the car with varying engine loads and RPM and read any trouble codes that are generated. Also check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed.
59. Set the right time on the clock.