24 00 033 Removing and installing automatic transmission (GA8HP45Z) N20 AWD

Special tools required :

IMPORTANT: To avoid severe damage to the engine block, the protruding threads of the transmission bolts must be checked for corrosion and damage prior to removal .
If the threads are corroded, they must be derusted and cleaned prior to removal .
Renew rusted, damaged screws.

Non-observance leads to severe 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!

Necessary preliminary tasks :

Clamp off BATTERY .
Remove REINFORCEMENT PLATE .
Remove EXHAUST SYSTEM .
Remove heat shields.
Remove front propeller shaft . See 26 11 051 REPLACING FLEXIBLE DISC FOR FRONT PROPELLER SHAFT or 26 20 000 REMOVING AND INSTALLING FRONT PROPELLER SHAFT .
Partially remove PROPELLER SHAFT .
- Disconnect propeller shaft at transmission.
- Release center mount.
- Tie up propeller shaft to underbody.
  NOTE: Bending the propeller shaft by an excessive angle can cause premature damage to the joint/propeller shaft!

Release screw (1).

Remove holder (2).

Fig 1: Holder Screw

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Release screws (1).

Tightening torque: 24 11 6AZ .

Remove the protective plate (2).

Fig 2: Protective Plate Screws

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Release screw (1) from ground strap (2).

Tightening torque: 24 11 7AZ .

Fig 3: Ground Strap Screw

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Version 1:

Unscrew nuts (1).

Tightening torque: 18 20 1AZ .

Unfasten screws (2).

Tightening torque: 18 20 2AZ .

Remove bracket (3) and catalytic converter (5).

Unscrew nuts (4).

Tightening torque: 18 20 1AZ .

Remove rubber mounts for catalytic converter.

Fig 4: Bracket, Catalytic Converter, Nuts, Screws

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Version 2:

Unscrew nuts (1).

Tightening torque: 18 20 1AZ .

Unfasten screws (2).

Tightening torque: 18 20 2AZ .

Remove holder (3) for catalytic converter.

Fig 5: Catalytic Converter Holder, Nuts And Screws

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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.

Fig 6: Hydraulic Lines Screw

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Release screws (1).

Tightening torque: 24 00 1AZ .

Remove cover (2).

Fig 7: Cover Screws

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

Undo all 6 bolts on torque converter.

Tightening torque: 24 40 1AZ .

IMPORTANT: Replace all 6 bolts on torque converter.

Fig 8: Vibration Damper Screw

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Unscrew knurled screw (1) from special tool 2 222 741 (do not remove completely) before inserting in the recess of the transmission housing.

Insert special tool 2 222 741 and shaped element (3) in the recess.

Slightly tighten knurled nut (2).

Screw in knurled screw (1) fully.

Locating pin (4) must be located between converter and engine.

Move special tool 2 222 741 in the recess until the locating pin (4) rests against the converter.

Use knurled nut (2) to fix special tool 2 222 741 and converter in position.

Fig 9: Removing Knurled Screw From Special Tool (2 222 741)

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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 TRANSMISSION BRACKET .

Fig 10: Supporting Transmission Using Special Tools (23 4 050/00 2 030)

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Release screws (1).

Tightening torque: 22 32 3AZ .

Slacken nut (2).

Tightening torque: 22 32 6AZ .

Release screw (3) and remove transmission cross-member (4).

Fig 11: Transmission Cross-Member Screw

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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 cup.

Tasks are described in Gearbox holder.

NOTES ON MECHATRONICS

IMPORTANT: Read and comply with important note.

Fig 12: Disconnecting Connector

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Disconnect connector (1) from transfer box control unit (longitudinal torque module) (2).

Fig 13: Transfer Box Control Unit Connector (Longitudinal Torque Module)

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Release wiring harness (1) from holder.

Fig 14: Holder Wiring Harness

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Release screws.

Tightening torque: 24 00 1AZ

Fig 15: Transmission Housing Bolts Tightening/Loosening Sequence

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Installation note :

Check that fitting sleeves (1) are correctly seated.

Replace damaged fitting sleeves.

Fig 16: Fitting Sleeves

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Installation note :

Twist torque converter until bore hole in torque converter is flush with bore hole of flywheel.

Flange automatic transmission to engine.