Installing automatic transmission

Checking installation position of torque converter 

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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 

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• Align the automatic transmission horizontal to the engine before installation.
• Check the fitting sleeves (1) for correct seating and damage and replace if necessary.

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• Flange-mount transmission.
• Turn the torque converter until the bore of the torque converter is aligned with the bore of the flywheel.
• Join the bolts (arrows) and hand-tighten.

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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.
  TIGHTENING TORQUES SPECIFICATION
  
  

  Front axle carrier to body, rear
  M14 Replace screw.	Joining torque	100 Nm
  	Angle of rotation	90°

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• Replace sealing rings.

  Parts:  Sealing ring

• Install hydraulic lines (2) on transmission.
• 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

• Install the transfer box with the front propeller shaft.
  NOTE: TECHNICAL INFORMATION 
  When assembling, it is essential to observe screwing sequences and tightening torques.
  Failure to comply with the regulations can lead to leaks and damage.
• Tighten screws in the sequence (1) to (5).
  Fig 1: Transfer Box Screws Tightening Sequence

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  TIGHTENING TORQUES SPECIFICATION
  
  

  Transfer box to automatic transmission
  M10	tightening torque	43 Nm

• Before installing the prop shaft on the front axle transmission, all 4 threads (1) in the front axle transmission flange must be freed of possible residue and contaminations and cleaned.

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• Replace screws.

  Parts:  Screws

• A drop of Loctite 270 (2) must be given before the screw connection on each thread at the end of the respective screw (1).
  CONSUMABLE SPECIFICATION
  
  

  High-strength screw lock, Loctite 270

  10 ml, Tube

  83 19 2 210 337

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  NOTE: TECHNICAL INFORMATION 
  After the screw connection of the front prop shaft, a 30 minute hardening time must be ensured before the vehicle is operated again.
• Tighten screws (arrows).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Prop shaft before the front axle differential
  Replace screws. Joining torque and angle of rotation must be observed without fail.	Tightening torque	25 Nm
  	Angle of rotation	45°

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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

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

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• Install the exhaust bracket (2).
• Position the screws (1) and hand-tighten.

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• Tighten nuts (1).

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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 2: Transmission Bolts Tightening Sequence

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• Connect the connector (1) on the VTG control unit (longitudinal torque distribution) (2).

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• Install the ground strap (2).
• Tighten down screw (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Ground strap to transmission or body
  M8	tightening torque	19 Nm

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• Version A: 
• Replace screws (1).

  Parts:  Screws

• Position transmission bearing support (2).
• Tighten down screws (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Transmission bearing support to body
  M8	Tightening torque	19 Nm

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• Version B: 
• Replace screws (1).

  Parts:  Screws

• Position transmission bearing support (2).
• Tighten down screws (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Transmission bearing support to body
  M8	Tightening torque	19 Nm

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• Install the transmission cross member (3).
• Tighten down screw (2).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Transmission cross member to rubber mounts
  M12	tightening torque	68 Nm

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• Tighten down screws (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Transmission cross member to body
  M8	tightening torque	19 Nm

• Remove the transmission jack.

Follow-up work 

• Refer to FASTENING THE PROP SHAFT (PARTIALLY REMOVED) .
• Refer to INSTALLING THE RETAINING PLATES .
• Refer to INSTALLING THE CONNECTING SUPPORTS ON THE TUNNEL .
• Refer to INSTALLING THE HEAT SHIELDS .
• Refer to INSTALLING EXHAUST SYSTEM .
• Refer to INSTALLING THE LEFT AND RIGHT REAR DIFFUSER .
• Refer to INSTALLING THE TENSION STRUT AT THE RIGHT REAR AND IF NECESSARY, ON THE LEFT SIDE .
• Refer to INSTALLING STARTER MOTOR .
• Refer to INSTALLING THE ACOUSTIC COVER FOR THE OIL SUMP .
• Refer to INSTALLING THE STIFFENING PLATE .
• Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
• Refer to CHECKING/TOPPING UP THE OIL LEVEL IN THE AUTOMATIC TRANSMISSION .
• Refer to INSTALLING UNDERBODY PROTECTION AT REAR .
• Refer to INSTALLING FRONT UNDERBODY PROTECTION .
• Refer to ENCODING/PROGRAMING CONTROL UNIT(S) .