Removing and Installing Transmission

Removing and Installing Transmission




- Disconnect battery ground lead.
- Unscrew nut (1).
- Disconnect throttle cable.
Installation:
- Adjust throttle cable. Adjustments




- Remove exhaust assembly
- Unscrew connector (1) and heat shield (2).




- Loosen cross member mounting bolts on right side enough that heat shield can be pulled out.




- Support transmission with Special Tools 24 0 120 and 00 2 020.
- Remove cross member.
Installation:
- Tightening torque: Mechanical Specifications




Version with Joint Disc:
- Unscrew joint disc on transmission.




Installation:
- Replace stop nuts.
- Tighten nuts with a standard 19 mm socket and torque wrench.
- Tightening torque*
IMPORTANT!
- Only tighten nuts (never bolts) to avoid stress in joint disc.




Version with Universal Joint:
- Unscrew propeller shaft on transmission.
Installation:
- Tighten nuts to correct torque*.




- Loosen screw-on ring (1) several turns.
Installation:
- Tighten screw-on ring (1) with Special Tool 26 1 040 after finishing installation.
- Tightening torque*




- Unscrew center mount.
Installation:
- Preload center mount forward by distance (A) = :4 to 6 mm (0.157 to 0.236"). Bend propeller shaft down and pull off of centering pin.
IMPORTANT!
- Suspend propeller shaft from car on piece of wire.
- Align propeller shaft.




- Drain oil.
IMPORTANT!
- Never reuse drained oil.
Installation:
- If oil smells burnt and is black, transmission will have to be disassembled.
IMPORTANT!
- If transmission was defective, clean oil cooler and lines with compressed air and flush twice with ATF.
- Remove oil filler tube (1).
- Unscrew oil cooler lines on transmission and insert caps in open connections.
- Tightening torque: Mechanical Specifications




- Remove reinforcement plate.
- Unscrew Torx bolts with a Torx socket.
Installation:
- Tightening torque: Mechanical Specifications
IMPORTANT!
Installation:
- Washers must be used on version with Torx bolts to avoid an increase in breaking loose torque.
- Tightening torque: Mechanical Specifications




- Unscrew torque converter on drive plate at three points, turning flywheel for this purpose.
IMPORTANT! - Installation:
- Only use size M 10 x 16 mm bolts together with spring washers.
- Tightening torque: Mechanical Specifications
- Nonconformance leads to destruction of the transmission.




- Unscrew guard.
- Unscrew bolts.
- Pull Out speed sensor (1) and reference mark sensor (2).
IMPORTANT!
Installation:
- Check installed position.
- Plugs must not be mixed up.
- Install speed sensor (1) in bore (D) and reference mark sensor (2) with ring (3) in bore (B).
- Engine cannot be started when plugs are mixed up.




Installation:
- Check O-rings.
- Install sensors with Molykote Longterm 2.
IMPORTANT!
- Face of DME sensors must be free of grease and dirt.




- Unscrew nut (2).
- Disconnect cable on holder.
- Pull Out cable.
Installation:
- Adjust cable 24 00 006.




Only for Version with EH Transmission:
- Turn bayonet fastener (1) to the left.
- Pull off plug (2).
- Lift wire harness out of holders.




- Lower and unscrew transmission on engine.
- Use a Torx socket** for Torx bolts.
- Lift off protective grill.
- Pull transmission off of engine, pressing off torque converter at same time.
IMPORTANT!
The special tool jack with a mounted transmission may only be moved in completely lowered position.
IMPORTANT! - Installation:
- Washers must be used on version with Torx bolts to avoid an increase in breaking loose torque.
Tightening torque: Mechanical Specifications




IMPORTANT! - Installation:
- Check installed position of torque converter. Drive ring must be located below edges of case.
Note:
Make sure that the converter stays in its installed position while installing, preventing it from sliding out if necessary.




Installation:
- Check drive plate for breaks and cracks, replacing if necessary.
- Hold flywheel with Special Tool 11 2 160.
- Unscrew expansion bolts.
IMPORTANT!
- Replace and install new expansion bolts with Loctite No.270.
- Only cost threads.
- Clean tapped bores thoroughly.
- Tightening torque: Mechanical Specifications