24 00 033 Removing And Installing Automatic Transmission (GA8HP45Z) N55 AWD

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Special tools required:

IMPORTANT: To prevent heavy damage to the engine block, the protruding thread of the transmission bolts absolutely must be checked for damage and corrosion before removal .
If there are signs of corrosion, the rust must be removed and the threads must be cleaned before removal .
Replace rusted, damaged screws.

Failure to comply with this instruction will result in serious damage to the engine block and transmission.

IMPORTANT:

Do not let skin come in contact with transmission oil and do not inhale fuel vapors.
Wear protective gloves.
Ensure adequate ventilation.

IMPORTANT: After completion of repair work, check TRANSMISSION OIL LEVEL .
Use only the approved transmission oil .
Failure to comply with this requirement will result in serious damage to the automatic transmission!

IMPORTANT: For vehicles with N54/N55 engine up to production date 09/2012, aluminum bolts for the for the securing of the transmission are also installed.
As of production date 09/2012, only steel bolts are installed for the securing of the transmission.

NOTE: Aluminum screws/bolts must be replaced each time they are released .
Aluminum screws/bolts are permitted with and without color coding (blue).
For reliable identification:
Aluminum screws/bolts are not magnetic .
Jointing torque and angle of rotation must be observed without fail (risk of damage) .
The aluminum bolts can be optionally replaced by steel bolts.

Necessary preliminary tasks:

Disconnect the battery . See 61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD or 61 20... INFORMATION ON AGM BATTERY .
Remove FAN COWL
Remove underbody protection at front and rear. See 51 47 490 REMOVING AND INSTALLING/REPLACING UNDERBODY PROTECTION (FRONT) or 51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION .
Remove REINFORCEMENT PLATE .
Important installation notes are described in this job item.
Remove both hose connectors on the charge air cooler on the left and right.
Remove EXHAUST SYSTEM .
Remove heat shields.
Release MONITORING SENSOR on catalytic converter.
REMOVE front propeller shaft.
Detach PROPELLER SHAFT at transfer box, release center mount.
Tie back propeller shaft to underbody.
Note:
Bending the propeller shaft by an excessive angle can cause premature damage to the joint/propeller shaft!
Support engine with jack when removing gearbox.

Remove upper part of cable duct (1).

Fig 1: Cable Duct Upper Part

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Release cable (1) from holder (2).

Release screw (3).

Remove cover (4).

Tightening torque: 24 00 2AZ .

Fig 2: Automatic Transmission Cable, Holder And Cover

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Check installed bracket position (1).

Fig 3: Bracket Position

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Release screws (1).

Slacken nut (2).

Remove bracket (3).

Tightening torque: 18 20 1AZ .

Fig 4: Automatic Transmission Screws, Nut And Bracket

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Release screw (1).

Disconnect hydraulic lines (2) to transmission oil cooler.

Tightening torque: 17 22 1AZ .

Installation note:

Replace sealing rings.

IMPORTANT: Keep to installation sequence.
Failure to observe this sequence will result in leaks.

1. Lower hydraulic line.
2. Upper hydraulic line.

Fig 5: Hydraulic Lines And Screw

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Crank engine at vibration damper in direction of rotation until screw (1) is visible in recess.

Release all 6 bolts of torque converter with special tool 24 1 110 .

Installation note:

Replace converter screws. Remove any remaining adhesive residue from the thread.

Tightening torque: 24 40 1AZ .

Fig 6: Torque Converter Screw

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Prepare special tool (1) 24 4 161 (A) with shaped element (2) 24 4 166 as pictured.

Fig 7: Special Tool (24 4 161)

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Insert special tool 24 4 160 into recess of transmission housing and clamp gently with screw (1).

Raise by turning screw (2) and clamp down.

Then tighten down screw (1).

Fig 8: Inserting Special Tool (24 4 160) Into Transmission Housing

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Supporting transmission:

Support transmission with special tools 23 4 050 , 00 2 030 .

Secure transmission to mounting with tensioning strap (1).

Tasks are described in GEARBOX HOLDER .

After completion of work, check transmission fluid level.

Fig 9: Supporting Transmission Using Special Tools

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Release screw (1) on left and right of axle.

Remove cover plate (2) on left and right of axle.

Remove bolt (3) on left and right of axle.

Tightening torque: 31 10 1AZ .

Fig 10: Axle Cover Plate, Screw And Bolt

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Screw on special tool 11 8 910 .

Fig 11: Special Tool (11 8 910)

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Adjust distance (1) between cross bar and facing using nuts (2).

Nuts (2) must be screwed down in opposite direction after distance has been adjusted.

IMPORTANT: Distance:

N55 38.5 mm

Fig 12: Cross Bar And Nut Distance

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Undo bolts (1) for gearbox mount.

Tightening torque: 22 32 10AZ .

Fig 13: Gearbox Mount Bolts

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Release screws.

Remove transmission cross-member (1).

Tightening torque: 22 32 3/4AZ .

Fig 14: Transmission Cross-Member And Screw

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Unplug connector (1) from transfer box control unit (longitudinal torque module).

Release screw (2).

Remove earth strap (3).

Fig 15: Transfer Box Control Unit Connector, Screw And Earth Strap

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Unlock and disconnect connector (1) by turning.
Do not touch pins.
Release cable from brackets.
Insert special tool 24 2 390 in sealing sleeve.

Repair work is described in NOTES ON MECHATRONICS .

IMPORTANT: Read and comply with important note.

Fig 16: Disconnecting Connector

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Release screws.

Installation note:

Observe screw fastening sequence without fail.

Tightening torque, steel screws 24 00 1AZ .

Aluminum screws must be replaced.

Tightening torque and angle of rotation, aluminum screws/bolts 24 00 2AZ (7, 8, 9, 10, 11).

Fig 17: Transmission Housing Bolts Tightening/Loosening Sequence

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Installation note:

Tighten down screws/bolts to specified torque.

Attach special tool 00 9 120 for angle of rotation with magnet 00 9 130 to vehicle underbody and screw down blue aluminum screws/bolts in accordance with angle of rotation.

Angle of rotation 24 00 2AZ .

Fig 18: Attaching Special Tool (00 9 120)

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Installation note:

Bore hole (1) of drive plate must be accessible from recess on engine oil sump. Check fitting sleeves (2...3) for correct seating.

Replace damaged fitting sleeves.

NOTE: Graphic representation similar.

Fig 19: Driving Plate Bore Hole And Sleeves

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Installation note:

Rotate torque converter until bore hole in torque converter is flush with bore hole in drive plate.

Flange automatic transmission to engine.