Installing automatic transmission (all-wheel drive vehicle) (GA8HP50Z)

NOTE: RISK OF DAMAGE
Damage to the transmission.
Damage to the transmission due to unapproved transmission oil.

Use only the approved transmission oil.
Check the transmission oil level after completing the repair.

NOTE: TECHNICAL INFORMATION
After completion of the work, program the control unit for the electronic gearbox control (EGS).

Checking installation position of torque converter

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NOTE: RISK OF DAMAGE
Damage to the automatic transmission/impeller.
When disconnecting the engine and transmission, the torque converter can become loose! Failure to observe the correct installation positions of the torque converter may lead to damage to the impeller driver.

Make sure that the torque converter is in the correct installation position before installing the automatic transmission.

Check the installation dimension between the contact surfaces (1) and the outer edge (2) of the threaded hole of the torque converter with the special tool 0 490 189 (00 2 550) .
See repair instructions
- REMOVING AND INSTALLING/REPLACING TORQUE CONVERTER

NOTE: RISK OF DAMAGE
Damage of the flywheel and automatic transmission.
A non-horizontal fit during the removal and installation of the automatic transmission can lead to damage on the automatic transmission or flywheel.

Align the automatic transmission completely horizontal to the engine during the removal and installation.
Check for correct alignment before tightening the transmission bolts.

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Before installing the automatic transmission, horizontally align it to the engine.

Checking lining sleeves

Check the fitting sleeves (1) for correct seating and damage and replace if necessary.

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Flange-mount transmission

Replace O-ring (1) .
The O-ring must be replaced before installing the front prop shaft in the transfer box (VTG).

Parts: O-ring

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Position the front prop shaft (1) on the output flange (3) of the transfer box (VTG).
Match the front prop shaft (1) with the marks (2) and (4) .
Slide the front prop shaft (1) up to the stop into the output flange (3) of the transfer box.

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Flange-mount the transmission on the transfer box (VTG).
Turn the torque converter until the bore of the torque converter is aligned with the bore of the drive plate.
Fit the transmission bolts (arrows) and apply lightly.

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Remove the special tool from the torque converter

Release screw (1) and screw (2) .
Remove the special tool 0 494 451 (24 4 160) .

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Install the sealing cap (1) .

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Tighten converter bolt

Replace screws (1) .
Parts: Screws
Turn the engine in the direction of rotation using special tool 0 493 380 (11 6 480) on the vibration damper to tighten all 6 screws (1) .
Tighten all 6 screws (1) of the torque converter using special tool 0 491 667 (24 1 110) .

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TIGHTENING TORQUE SPECIFICATIONS

Torque converter to flywheel
M10 Replace screws.	tightening torque	56 Nm

Install acoustic cover

Install the acoustic cover (2) .
Install the expanding rivet (1) .

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Install the exhaust bracket

Install the exhaust bracket (2) .
Tighten the screws (1) .

TIGHTENING TORQUE SPECIFICATIONS

Transmission to engine
M8	Tightening torque	19 Nm
M12	Tightening torque	66 Nm

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Tighten nuts (1) .

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Lock the connector with the sealing sleeve

Remove the special tool 0 494 213 (24 2 390) in arrow direction from the sealing sleeve.

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NOTE: TECHNICAL INFORMATION
Notes on mechatronics are a fundamental requirement for these repair instructions and must be complied with at all times.
For additional information see the Notes on mechatronics below.

Slide the connector (1) on and turn it to lock.

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Notes on mechatronics

CAUTION: Materials harmful to health.
Contact with fluids harmful to health!

Note and follow safety instructions on containers.
Conduct all work in appropriate personal protective equipment only.

NOTE: RISK OF DAMAGE
Damage to the automatic transmission after removal of the mechatronics.
Serious damage to the automatic transmission due to non-compliance with the following tasks:

Load specific data status with the diagnostic system.
Use only approved transmission oil.
After completion of repair work, check the transmission oil level.

NOTE: RISK OF DAMAGE
Electrostatic discharge.
Damage to or destruction of electrical components.

Leave the electrical components in their original packaging until they are being installed. Only use the original packaging for returning the product. Always package removed components straight away.
Read and comply with user information on using the associated special tool 12 7 060.
Only tap the housings of electrical components. Do not tap pins or multi-pin connectors directly.
Wear electrically conductive clothing and antistatic shoes (with ESD symbol).
For additional information see: NOTES ON ESD (ELECTROSTATIC DISCHARGE) PROTECTION .

Tighten transmission screws

Tighten the transmission bolts in sequence (1) to (9) .

TIGHTENING TORQUE SPECIFICATIONS

Transmission to engine
M8	Tightening torque	19 Nm
M12	Tightening torque	66 Nm

Fig 1: Transmission Bolts Tightening Sequence

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Fix hydraulic lines

Replace sealing rings.
Parts: Sealing ring
Install hydraulic lines (2) on transmission.
Position and tighten the screw (1) .

TIGHTENING TORQUE SPECIFICATIONS

Transmission oil line to transmission
M6x25 Replace the sealing ring.	tightening torque	8 Nm

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Connecting the connector with the VTG control unit

Connect the connector (1) to the VTG control unit for the longitudinal torque distribution (2) .

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Install the ground strap

Install the ground strap (2) .
Tighten down screw (1) .

TIGHTENING TORQUE SPECIFICATIONS

Ground strap to transmission or body
M8	tightening torque	19 Nm

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Installing transmission cross member.

Install the transmission cross member.
Tighten down screws (2) .

TIGHTENING TORQUE SPECIFICATIONS

Transmission cross member to body
M8	tightening torque	19 Nm

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Tighten down screw (1) .

TIGHTENING TORQUE SPECIFICATIONS

Transmission cross member to rubber mounts
M12	tightening torque	68 Nm

Remove the transmission jack

Release the luggage strap (1) from the transmission.
Remove the special tools 0 495 498 (23 4 050) and 2 219 012 from the transmission.

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Follow-up work

Refer to FASTENING THE PROP SHAFT (PARTIALLY REMOVED) .
Refer to INSTALLING THE RETAINING PLATES .
Refer to INSTALLING THE HEAT SHIELDS .
Refer to INSTALLING THE COMPLETE EXHAUST SYSTEM .
Refer to INSTALLING THE REAR DIFFUSER .
Refer to IF INSTALLED: INSTALLING THE TORSION STRUT ON THE RIGHT, AND ON THE LEFT WHERE REQUIRED .
Refer to INSTALLING THE CONNECTING SUPPORTS ON THE TUNNEL .
Refer to INSTALLING THE REAR AXLE COVER .
Refer to CONNECTING ALL BATTERY GROUND LEADS .
Refer to CHECKING/TOPPING UP THE OIL LEVEL IN THE AUTOMATIC TRANSMISSION .
Refer to INSTALLING REAR UNDERBODY PROTECTION .
Refer to INSTALLING THE UNDERBODY PLANKING OF THE TRANSMISSION ON THE SIDE .
Refer to IF THE ACTIVE STABILIZER IS INSTALLED: INSTALLING FAN COWL .