Installing Output Flange Retrofit Kit

Caution: Risk of burning; allow car to cool down before working on exhaust system.

Car stationary, transmission selector lever in position "P".
After completing work, top up ATF level.
Check/top up fluid level in automatic transmission, refer to Automatic Transmission Fluid, Testing and Inspection.

Caution:
It is absolutely essential to use the approved automatic transmission fluid in this automatic transmission.
Failure to comply with this requirement will result in serious damage to the automatic transmission!





Installation: Replace self-locking nuts.
Coat thread with suitable copper paste.





Check seals (1), replace if necessary.





Support exhaust system with lifter and special tool 31 2 220 and secure against failing out.





Release bolts (1/2) and remove reinforcement plate (3), front reinforcement plate is connected by rubber mount to exhaust system





Release screw (1) and remove exhaust bracket.

Installation:
After complete installation of exhaust system, align exhaust bracket so that it is free of tension; slacken screws (2) for this purpose.





Front rubber mount on rear muffler, release hexagon nuts (1 ).





Rear rubber mount on rear muffler, release hexagon nuts (1).
Remove complete exhaust system.





Remove heat shield (1).





Unfasten screws.

Installation:
Replace self-locking nuts.
Tightening Torque, refer to Automatic Transmission/Transaxle, Specifications.





Grip propeller shaft and release nuts.
Bend propeller shaft downwards at center mount (1), detach from transmission output flange and tie back to one side on underbody of vehicle.

Installation:
Tightening Torque, refer to Automatic Transmission/Transaxle, Specifications.





Grip output flange (1) with special tool 23 0 020.
Release hexagon nut.
Detach output flange (1).





Preparing retrofit kit:
1. Snap ring
2. O-ring
3. Output flange
4. Spring washer
5. Flat nut





Coat O-ring (1) with transmission fluid and insert in groove of output flange (2).





Push snap ring (1) onto splined shaft (2) taking care not to damage shaft seal.





Push output flange (2) onto output shaft and install spring washer (1)
Observe installation direction of spring washer (1).





Mount nut (1) on output flange (2).

Installation:
Tightening Torque, refer to Automatic Transmission/Transaxle, Specifications.