Installing the automatic transmission (all-wheel drive vehicle) (GA8HP75HZ)

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).

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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Align the automatic transmission horizontal to the engine before installation.
Check for correct fit of lining sleeves (1).

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Before installing the front prop shaft in the transfer box (VTG), replace the O-ring (1).
Parts: O-ring

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Position the front prop shaft (1) on the output flange (3) of the transfer box (VTG).
Align marks (2) and (4).
Push front prop shaft (1) to stop in output flange (3) of transfer box (VTG).

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Flange-mount the transmission on the transfer box (VTG).
Replace the bolts (arrows).
Parts: Screws
Join the bolts (arrows) and hand-tighten.

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Remove the special tool 0 494 213 (24 2 390) in arrow direction from the sealing sleeve (1).

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

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Connect connectors (1) and lock.

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Install the line (2).
Connect connectors (1) and lock.

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Install the connector (2).
Replace the screw (1).
Parts: Screw

Tighten down screw (1).

TIGHTENING TORQUE SPECIFICATIONS

Standard screw connection
M6	Tightening torque	8 Nm

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Connect connectors (1) and lock.

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Install the exhaust bracket (2).
Replace screws (1).
Part: Screws
Hand-tighten the screws (1).

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Replace nuts (1).
Parts: Nuts

Tighten nuts (1).

TIGHTENING TORQUE SPECIFICATIONS

Catalytic converter to holder
M8 Nut Replace nut.	tightening torque	28 Nm

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Tighten screws in the order (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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Feed in and install transmission oil lines (2).
Replace the screw (1).
Parts: Screw

Tighten down screw (1).

TIGHTENING TORQUE SPECIFICATIONS

Transmission oil lines to thermostat/automatic transmission
M6X25	Tightening torque	8 Nm

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Feed in and install transmission oil lines (2).
Replace the screw (1).
Parts: Screw

Tighten down screw (1).

TIGHTENING TORQUE SPECIFICATIONS

Transmission oil lines to thermostat/automatic transmission
M6X25	Tightening torque	8 Nm

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

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Insert and install the holder (2).
Replace screws (1).
Parts: Screws

Tighten down screws (1).

TIGHTENING TORQUE SPECIFICATIONS

Holder of high-voltage cable to automatic transmission
M6X12	Tightening torque	8 Nm

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Position the high-voltage cable (1) on the holder (3) in the direction of the arrow.
Insert and install the holder (2).

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Position holder (2).
Replace the screw (1).
Parts: Screw

Tighten down screw (1).

TIGHTENING TORQUE SPECIFICATIONS

High-voltage cable to holder
M6x12/M6x14	Tightening torque	8 Nm

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Unlock the clamps (1).
Remove special tool 5 A29 F40 from high-voltage connector (2).

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Guide in and install the high-voltage connector (2).
Replace screws (1).
Parts: Screws
Hand-tighten the bolts (1) crosswise up to the high-voltage connector (2).

Tighten screws (1) crosswise.

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TIGHTENING TORQUE SPECIFICATIONS

High-voltage cable to automatic transmission
M6X25 Tighten screws in crosswise sequence.	Joining torque	3 Nm
	Tightening torque	8 Nm

WARNING: Potential equalization in high-voltage system.
Mortal hazard if the potential equalization screw connection is not correct!

Observe the safety requirements for the potential equalization screw connection.
Clean contact faces and have then checked by a second person.
Tighten the screws/nuts for potential equalization with torque; have a second person check the torque.
Correct execution of these tasks must be documented in the vehicle records by both persons.

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Install the ground strap (2).
Replace nut (1).
Parts: Nut

Tighten nut (1).

TIGHTENING TORQUE SPECIFICATIONS

Ground strap to transmission or body
M8	tightening torque	19 Nm

Clip the positive battery cable (2) into the clamps (1).

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Replace screws (1).
Parts: Screws

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

TIGHTENING TORQUE SPECIFICATIONS

Transmission bearing support to body
M8	Tightening torque	19 Nm

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Install holder (2).
Replace screws (1).
Parts: Screws

Tighten down screws (1).

TIGHTENING TORQUE SPECIFICATIONS

Retaining plates for vehicle underbody cover
Sheet metal nut/plastic nut Replace nuts.	tightening torque	3 Nm

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Install holder (4).
Replace screws (3).
Parts: Screws
Tighten down screws (3).

TIGHTENING TORQUE SPECIFICATIONS

Retaining plates for vehicle underbody cover
Sheet metal nut/plastic nut Replace nuts.	tightening torque	3 Nm