24 00 033 Removing And Installing Automatic Transmission (GA8HP45Z)

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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: 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) .

Necessary preliminary tasks:

Disconnect the battery . See 61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD or 61 20... INFORMATION ON AGM BATTERY .
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 PROPELLER SHAFT .
Loosen MONITORING SENSOR , cylinders 1-3.
Support engine with jack when removing gearbox.

Unfasten ground strap (1).

Remove retaining plates (2).

Fig 1: Ground Strap And Retaining Plates

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Release cable (1) from holder (2).

Fig 2: Cable And Holder

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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 3: Hydraulic Lines And Screw

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Release coolant hose (1) from holder (2) and lay to one side.

Fig 4: Coolant Hose And Holder

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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 5: Torque Converter Screw

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Unscrew nuts (1).

Tightening torque: 18 20 2AZ .

Fig 6: Bracket Nut

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Disengage monitor sensor cable (2) from holder.

Release screws (1).

Remove exhaust bracket (3).

Tightening torque: 18 20 6AZ .

Fig 7: Monitor Sensor Cable, Exhaust Bracket And Screws

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Disconnect connectors (1) and (2) from bracket (3) and detach.

Fig 8: Automatic Transmission Connectors And Bracket

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Release screws (3), (4) and (9).

Remove cable clip.

NOTE: Aluminum screws must be replaced.

Tightening torque: 24 00 1AZ/2AZ .

Fig 9: Transmission Housing Bolts Tightening/Loosening Sequence

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

Fig 10: 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 11: Inserting Special Tool (24 4 160) Into Transmission Housing

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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.

Operations are described in:

NOTES ON MECHATRONICS .

IMPORTANT: Read and comply with important note.

Fig 12: Disconnecting Connector

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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 13: Axle Cover Plate, Screw And Bolt

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Screw on special tool 11 8 910 .

Fig 14: 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: 38.5 mm

Fig 15: Cross Bar And Nuts Distance

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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 16: Supporting Transmission Using Special Tools

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Unscrew nut (1) and bolts (2).

Remove gearbox cross member (3).

Tightening torque: 22 32 3/4AZ .

Fig 17: Gearbox Cross Member, Nut And Bolts

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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 18: 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 19: Attaching Special Tool (00 9 120)

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Installation note:

Bore hole (1) of driving plate must be accessible from recess on engine oil sump. Check that fitting sleeves (2...3) are correctly seated.

Replace damaged fitting sleeves.

NOTE: Graphic representation similar.

Fig 20: 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.