Installing automatic transmission (all-wheel drive vehicle) (GA8HP51Z)

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

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.

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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, align it horizontally to the engine.
Check the fitting sleeves (1) for correct fit and damage and replace as needed.

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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).
Align the marks (2) and (4) of the front prop shaft (1).
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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Turn the knurled screw (2) until the plate (3) is no longer in contact.
Release screws (1) and remove the special tool 5 A0C 1B9.

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Replace screws (1).
Parts: Screws
Tighten the screws (1) on the front axle support.

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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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Replace screws.
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) .

TIGHTENING TORQUES SPECIFICATION

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

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

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

TIGHTENING TORQUES SPECIFICATION

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

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Tighten nuts (1).

TIGHTENING TORQUES SPECIFICATION

Catalytic converter to holder
M8 copper-plated nut Replace nut.	Tightening torque	28 Nm
M8 zinc-plated nut	Tightening torque	19 Nm

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

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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.

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Slide connector (1) in the arrow direction and lock it by turning it.
Tighten the transmission bolts in the sequence (1) to (9).

TIGHTENING TORQUES SPECIFICATION

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

Fig 1: Transfer Box Screws Tightening Sequence

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

TIGHTENING TORQUES SPECIFICATION

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

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Position and tighten the screw (3).

TIGHTENING TORQUES SPECIFICATION

Transmission oil line on holder
M6	Tightening torque	4 Nm

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

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Guide in and install wiring harness section (3) of the supply module.
Tighten down screw (1).

TIGHTENING TORQUES SPECIFICATION

Grounding cable to transmission
BM6	Tightening torque	8 Nm

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Connect connectors (2) and lock.
The connector (2) must engage audibly.
Install the ground strap (2).
Tighten down screw (1).

TIGHTENING TORQUES SPECIFICATION

Ground strap to transmission/body
M8	Tightening torque	19 Nm

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Remove transmission mounting bracket (2) on the right transmission side.
Replace screws (1).
Parts: Screws
Tighten down screws (1).

TIGHTENING TORQUES SPECIFICATION

Transmission mounting bracket to transmission
M8	Replace screws. Tightening torque	28 Nm

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Version A:
Install transmission bearing support holder (3).
Tighten down screws (2).

TIGHTENING TORQUES SPECIFICATION

Transmission bearing support to body
M8	Tightening torque	19 Nm

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Tighten the vibration absorber (1).

TIGHTENING TORQUES SPECIFICATION

Rubber mount to transmission bearing support
M8	Tightening torque	19 Nm

Version B:
Install transmission bearing support holder (3).
Tighten down screws (2).

TIGHTENING TORQUES SPECIFICATION

Transmission bearing support to body
M8	Tightening torque	19 Nm

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Tighten nut (1).

TIGHTENING TORQUES SPECIFICATION

Rubber mount to transmission bearing support
M8	Tightening torque	19 Nm

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

TIGHTENING TORQUES SPECIFICATION

Transmission cross member to body
M8	Tightening torque	19 Nm

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Tighten down screw (1).

TIGHTENING TORQUES SPECIFICATION

Transmission cross member to rubber mounts
M12	tightening torque	68 Nm

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 EXHAUST SYSTEM .
Refer to INSTALLING THE CONNECTING SUPPORTS ON THE TUNNEL .
Refer to INSTALLING TANK COVER ON LEFT AND RIGHT .
Refer to ACTIVATING ELECTRICAL SYSTEM .
Refer to ACTIVATING THE 48 V ELECTRICAL SYSTEM .
Refer to CHECKING/TOPPING UP THE OIL LEVEL IN THE AUTOMATIC TRANSMISSION .
Refer to IF INSTALLED: INSTALLING THE UNDERBODY PLANKING OF THE TRANSMISSION ON THE SIDE .
Refer to INSTALLING UNDERBODY PROTECTION AT REAR .
Refer to INSTALLING THE CENTER UNDERBODY PROTECTION .
Refer to INSTALLING FRONT UNDERBODY PROTECTION .