Removal Of Automatic Transmission From Engine

REMOVAL 

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1. Loosen the clamp (1) securing the left catalytic converter to the turbocharger.
2. Release the front and rear oxygen sensor wires from the retainers (2).

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3. Remove the mounting bracket bolts (1a) and remove the left catalytic converter (1b).

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4. Loosen the clamp (1) securing the right catalytic converter to the turbocharger.
5. Release the front and rear oxygen sensor wires from the retainers (2).

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6. Remove the mounting bracket bolts (1a) and remove the right catalytic converter (1b).

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7. Remove the bracket bolt (1), securing the automatic transmission fluid supply and return duplex pipe to the cooling radiator, release it from the right intake manifold and move it to one side.

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8. Remove the thermostatic valve mounting bracket (1b) bolt (1a).

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9. Open the clip (1) and release the wiring.
10. Remove the nuts (2a), the bolt (2b) and remove the thermostatic valve mounting brackets (2c).

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11. Loosen the clamps (1) and disconnect the coolant supply and return pipes from the automatic transmission oil heat exchanger.
12. Remove the bolts (2) and release the support, complete with automatic transmission oil heat exchanger.

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13. Remove the bolt (1a) and remove the retainer plate (1b) of the automatic transmission fluid supply and return pipe connectors.
14. Disconnect the automatic transmission fluid supply and return rigid pipe connectors (2).

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15. Remove the bolt (1a) and remove the oil supply/return pipes (1b), complete with automatic transmission oil heat exchanger.

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16. Open the clamps and disconnect the air outlet pipes (1) from the turbochargers.
17. Remove the stud bolts (2a), nuts (2b), and release the turbocharger air-water heat exchangers (2c).

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18. Remove the bolts (1) securing the pipes from heat exchangers to throttle bodies.
19. Remove the upper bolts (2) securing the turbocharger air-water heat exchangers.
20. Remove the turbocharger air-water heat exchanger assembly (3) complete with pipes.

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21. Remove the bolts (1a) and remove the heat shield (1b) of the front drive shaft.

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22. Remove the bolts (1a) securing the front wheel drive shaft (1b) to the transfer case and remove the spacers.

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23. Release the dust seal ring (1a) from the front wheel drive shaft (1b).

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24. Release the circlip (1a) locking the front wheel drive transmission shaft (1b), on the differential pinion side.

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25. Use a suitable soft mallet to remove the front wheel drive shaft (1a) from the transfer case flange (1b).

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26. Using suitable tools and hydraulic lifts, support the engine and automatic transmission as shown in illustration.

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27. Position the (special tool #2024200090, Damper, Rotating Tool) (1) on the engine crankshaft service pulley.

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28. Remove the side cover (1) from the transmission bell housing, to access the torque converter to the engine flexplate bolts.

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29. Turn the engine crankshaft to access and remove the six torque converter to the engine flexplate bolts (1).

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30. Remove the upper and side nuts (1) securing the automatic transmission to the engine.

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31. Remove the automatic transmission bottom retaining nuts (1).

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32. Separate and remove the automatic transmission, complete with torque converter.
33. When detaching the transmission from the engine, position a suitable tool to withhold the torque converter in its housing. Take care because the torque converter contains transmission fluid.

INSTALLATION 

1. Check that the automatic transmission centering bushings are correctly housed on the engine crankcase.
2. Check and clean the threads on the torque converter housing the bolts of the engine flexplate.
3. Lubricate the torque converter centering seat using suitable grease.

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4. Check that the torque converter is positioned correctly by verifying that the distance between point "a" on the torque converter and surface "b" of the transmission bell housing is 51 mm.

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5. Install the transmission (1) complete with torque converter, and tighten the nuts securing it to the engine to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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6. Tighten the automatic transmission bottom retaining nuts (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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7. Tighten the automatic transmission side and upper retaining nuts (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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8. Position the (special tool #2024200090, Damper, Rotating Tool) (1) on the engine crankshaft service pulley.

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9. Turn the engine crankshaft to access and tighten the six torque converter to the engine flexplate bolts (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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10. Place the transmission bell housing side shield (1) back in its housing.
11. Remove the counter torque tool from the engine crankshaft service pulley.
12. Remove the automatic transmission support tools.

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13. Place the front drive shaft (1a) back in its housing, engaging it with the flange on the transfer case (1b).

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14. Use the tool (1a) to engage the circlip locking the front drive shaft (1b), on the differential pinion side.

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15. Engage the dust seal ring (1a) on the front drive shaft (1b).

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16. Use a suitable counter torque tool to tighten the bolts (1a) securing the front drive shaft (1b) to the transfer case, complete with spacers, to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .

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17. Install the heat shield (1a) of the front drive shaft and securely tighten the bolts (1a).

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18. Place the turbocharger air-water heat exchanger assembly (1), complete with pipes, back in its housing.
19. Securely tighten the upper turbocharger air-water heat exchangers bolts (2).
20. Securely tighten the bolts (3) securing the pipes from the turbocharger air-water heat exchangers to the throttle bodies.

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21. Tighten the stud bolts (1a) and nuts (1b) securing the turbocharger air-water heat exchangers (1c).
22. Connect the air outlet pipes from the turbochargers and securely tighten the clamps (2).

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23. Install the automatic transmission oil supply/return pipes (1a), complete with transmission oil heat exchanger, and securely tighten the bolt (1b).

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24. Connect the transmission oil delivery and return pipe connectors (1).
25. Install the retainer plate (2a) of the transmission oil supply and return pipe connectors and securely tighten the bolt (2b).

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26. Install the support complete with automatic transmission oil heat exchanger and securely tighten the bolts (1).
27. Connect the water supply and return pipes from the automatic transmission oil heat exchanger and securely tighten the clamps (2).

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28. Install the mounting brackets (1a) of the thermostatic valve and securely tighten the nuts (1b) and bolt (1c).
29. Engage the wire harness and close the retaining clip (2).

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30. Securely tighten the thermostatic valve mounting bracket (1b) bolt (1a).

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31. Install the mounting bracket of the automatic transmission oil supply and return duplex pipe to the cooling radiator and securely tighten the bolt (1).

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32. Install the right catalytic converter (1a) and tighten the mounting bracket bolts (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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33. Engage the front and rear oxygen sensor wires into the intermediate retainers (1).
34. Tighten the right catalytic converter to the turbocharger clamp (2) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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35. Install the left catalytic converter (1a) in its position and tighten the mounting bracket bolts (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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36. Engage the front and rear oxygen sensor wires into the intermediate retainers (1).
37. Tighten the left catalytic converter to the turbocharger clamp (2) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .