Installing automatic transmission (all-wheel drive vehicle) (GA8HP95Z)

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

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

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Tighten converter bolt

Replace screws.
Parts: Screws

Observe tightening sequence!
The torque converter must always be screwed to the vertically arranged elongated hole (1) first.
Turn the torque converter until the elongated hole (1) is visible in the opening!
Tighten down screw.

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TIGHTENING TORQUE SPECIFICATIONS

Torque converter to flywheel
M10 Replace screws.	tightening torque	60 Nm

Observe the tightening sequence of the additional 5 screws (torque converter on flywheel) compulsorily . For this purpose, see the following figure.
Tightening sequence: 1 - 4 - 3 - 6 - 5 - 2
Screw connection (1) = vertically arranged, elongated hole in torque converter

TIGHTENING TORQUE SPECIFICATIONS

Torque converter to flywheel
M10 Replace screws.	tightening torque	60 Nm

Fig 1: Torque Converter Screws Tightening Sequence

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Connecting the pulse generator connector

Connect the connector (2) and secure using the lock (1) .

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Securing the lines

Secure the lines (3) .
Tighten down screw (1) .
Tighten down screw (2) .

TIGHTENING TORQUE SPECIFICATIONS

Standard screw connection M5
M5	5 Nm

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Install the exhaust bracket

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

TIGHTENING TORQUE SPECIFICATIONS

Transmission to engine
M8	tightening torque	19 Nm
M10	tightening torque	38 Nm

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Replace screws (1) .
Parts: Screws
Tighten down screws (1) .

TIGHTENING TORQUE SPECIFICATIONS

Catalytic converter to holder
M8 Replace screws.	28 Nm

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

TIGHTENING TORQUE SPECIFICATIONS

Transmission to engine
M8	tightening torque	19 Nm
M10	tightening torque	38 Nm

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Replace screws (1) .
Parts: Screws
Tighten bolts (1) of catalytic converter (2) .

TIGHTENING TORQUE SPECIFICATIONS

Catalytic converter to holder
M8 Replace screws.	28 Nm

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Tighten transmission screws

Tighten screws (arrows).

TIGHTENING TORQUE SPECIFICATIONS

Transmission to engine
M8	tightening torque	19 Nm
M10	tightening torque	38 Nm

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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.

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

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 .

Follow-up work

Refer to INSTALLING THE CATALYTIC CONVERTER FOR CYLINDERS 7 TO 12 .
Refer to SECURING THE JUNCTURE SHAFT IN FRONT ON THE FRONT AXLE DIFFERENTIAL .
Refer to INSTALLING THE CATALYTIC CONVERTER FOR CYLINDERS 1 TO 6 .
Refer to INSTALLING THE TRANSFER BOX (ATC 13-1) .
Refer to CHECKING/TOPPING UP THE TRANSFER BOX OIL (ACTIVE TORQUE CONTROL 13-1) .
Refer to FASTENING THE PROP SHAFT (PARTIALLY REMOVED) .
Refer to INSTALLING TRANSMISSION CROSS MEMBER .
Refer to SCREW THE TRANSMISSION BEARING SUPPORT TIGHT (ALL-WHEEL DRIVE VEHICLE) .
Refer to INSTALLING THE HEAT SHIELDS .
Refer to CONNECTING TRANSMISSION OIL LINES .
Refer to INSTALLING EXHAUST SYSTEM .
Refer to INSTALLING THE CONNECTING SUPPORTS ON THE TUNNEL .
Refer to INSTALLING BOTH TRIM PIECES FOR THE EXHAUST TAILPIPE .
Refer to INSTALLING THE TRIM ON THE REAR BUMPER PANEL .
Refer to INSTALLING THE REAR DIFFUSER .
Refer to INSTALLING THE STIFFENING PLATE .
Refer to INSTALLING THE UNDERBODY PROTECTION OF THE STEERING GEAR OR THE FRONT THRUST FIELD .
Refer to INSTALLING THE FRONT UNDERBODY PROTECTION OR FRONT THRUST FIELD .
Refer to CONNECTING ALL BATTERY GROUND LEADS .
Refer to CHECK/TOPPING UP THE OIL LEVEL IN THE AUTOMATIC TRANSMISSION (GA8HP95Z) .
Refer to INSTALLING THE UNDERBODY PLANKING OF THE TRANSMISSION ON THE SIDE .
Refer to INSTALLING REAR UNDERBODY PROTECTION .
Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT CENTER .
Refer to INSTALLING THE RIGHT OXYGEN SENSOR MONITOR .
Refer to INSTALLING THE RIGHT LAMBDA OXYGEN SENSOR .
Refer to INSTALLING THE LEFT LAMBDA OXYGEN SENSOR .
Refer to INSTALLING THE RIGHT-HAND CHARGE AIR PIPE .
Refer to INSTALLING CHARGE AIR PIPE ON LEFT .
Refer to INSTALLING TOP RIGHT CLEAN AIR PIPE .
Refer to INSTALLING TOPPING CLEAN AIR PIPE ON LEFT .
Refer to INSTALLING THE RIGHT THROTTLE BODY .
Refer to INSTALLING THE LEFT THROTTLE BODY .
Refer to INSTALLING THE CENTER COWL UPPER PART .
Refer to INSTALLING TENSION STRUT ON SHOCK TOWER .
Refer to INSTALLING WINDSHIELD PANEL COVER .
Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
Refer to INSTALLING FAN COWL .
Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
Refer to INSTALLING LEFT INTAKE PORT .
Refer to INSTALLING THE LEFT-HAND AIR DUCT .
Refer to INSTALLING RIGHT AIR DUCT .
Refer to INSTALLING RIGHT INTAKE SILENCER HOUSING .
Refer to INSTALLING LEFT INTAKE SILENCER HOUSING .
Refer to INSTALLING FANFARE HORN, RIGHT .
Refer to INSTALLING THE FANFARE ON THE LEFT SIDE .
Refer to INSTALLING THE CENTER TOP CROSS CONNECTION .
Refer to INSTALLING BOTH HEADLIGHTS .
Refer to INSTALLING BUMPER COVER, FRONT .
Refer to INSTALLING FRONT SECTION OF THE FRONT WHEEL ARCH COVER (PARTIALLY REMOVED) .
Refer to INSTALLING FRONT ORNAMENTAL GRILLE .
Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT CENTER .
Refer to ADJUSTING HEADLIGHTS .
Refer to INSTALLING THE REAR RIGHT ENGINE COMPARTMENT COVER .
Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT ON THE REAR LEFT .
Refer to INSTALLING THE FRONT HOOD SEAL AT THE REAR .
Refer to INSTALLING ACOUSTIC COVER .