Removing the automatic transmission (all-wheel drive vehicle)

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Preliminary work

Refer to DEACTIVATING ELECTRICAL SYSTEM .
Refer to REMOVING RESONATOR .
Refer to REMOVING THE FRONT UNDERBODY PROTECTION .
Refer to REMOVING THE CENTER UNDERBODY PROTECTION .
Refer to REMOVING REAR UNDERBODY PROTECTION .
Refer to IF INSTALLED: REMOVING THE UNDERBODY PLANKING OF THE TRANSMISSION ON THE SIDE .
Refer to REMOVING TANK COVER ON LEFT AND RIGHT .
Refer to REMOVING THE CONNECTING SUPPORT FROM THE TUNNEL .
Refer to REMOVING EXHAUST SYSTEM .
Refer to REMOVING STARTER MOTOR .
Refer to REMOVING THE HEAT SHIELDS .
Refer to REMOVING THE RETAINING PLATES .
Refer to PARTIALLY LOOSENING THE PROP SHAFT .

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 engine block.
Serious damage to the engine block and transmission due to damaged and corroded screws.

It is imperative that protruding threads of the transmission bolts are checked for corrosion and damage prior to removal.
It is imperative that all rust is removed from corroded threads and that they are cleaned prior to removal.
Replace rusted and damaged bolts.

Remove transmission crossmember

Support the transmission using special tools 0 495 498 (23 4 050) and 2 219 012 .
Secure the transmission with a tensioning strap (1).

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Loosen screw (1).
Loosen screws (2).
Remove transmission cross-member.

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If installed: Releasing the transmission bearing support

Loosen the screws (1) on the transmission bearing support (2).

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Loosen ground strap from transmission

Release the screw (1) and release the ground strap (2).

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Disconnecting the connector from VTG control unit

Disconnect the connector (1) from VTG control unit (2).

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Disconnect hydraulic lines on the transmission

Loosen screw (1).
Disconnect hydraulic lines (2) to transmission oil cooler.

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Removing the acoustic cover

Pull the expanding rivet (1) off.
Remove the acoustic cover (2).

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Release converter bolt

Turn the engine on the vibration damper with the special tool 0 493 380 (11 6 480) in the direction of rotation until the bolt (1) becomes visible in the recess.
Release all 6 screws (1) the torque converter.

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Securing the torque converter

Prepare the special tool 0 494 478 (24 4 161) (1) with the special tool 0 494 965 (24 4 165) (2) as shown.

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Remove sealing cap (1).

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Insert special tool 0 494 451 (24 4 160) into the recess of the transmission housing and apply slight tension using the screw (1).
Screw the bolt (2) in to the stop.
Tighten down screw (1).

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Disconnecting the connector from the sealing sleeve

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

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Unlock the connector (1) by turning and disconnect.
Do not touch pins.
Loosen all cable clips.
Insert the special tool 0 494 213 (24 2 390) in the sealing sleeve (1) in arrow direction.

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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 PROTECTION (ELECTRO STATIC DISCHARGE) .

Releasing the front prop shaft on the front axle transmission

Remove screws (arrows).
Securely tie the prop shaft to the transmission with a belt.

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Undo remaining Torx screws

Support the engine.
Release remaining screws.
Remove the transmission with transfer box and front prop shaft.

Fig 1: Transfer Box Screws Loosening Sequence

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