Installing automatic transmission (all-wheel drive vehicle) (GA8HP76Z)

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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• Before installing the automatic transmission, horizontally align it to the engine.
• Check the fitting sleeves (1) for correct seating and damage and replace if necessary.

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• Transmission flange-mount.
• Twist the torque converter until the bore of the torque converter is flush with the bore of the flywheel.
• Fit the transmission bolts (arrows) and apply hand-tight.

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

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• Replace screws.

  Parts:  Screws

• First  screw the torque converter onto the vertically arranged elongated hole (1).

  It is compulsory to screw the torque converter onto the vertically arranged elongated hole (1) first.

• Rotate the engine on the vibration damper in direction of rotation 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 five screws (torque converter on flywheel) compulsorily  :

  Tightening sequence: 1 - 4 - 3 - 6 - 5 - 2 

  The screw connection (1) is the vertically arranged elongated hole in the torque converter.

  TIGHTENING TORQUE SPECIFICATIONS
  
  

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

  Fig 1: Torque Converter To Flywheel Screws Tightening Sequence

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• Install the sealing cap (1).

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• Install the exhaust bracket (3).
• Position the screws (1) and hand-tighten.
• Replace screws (2).

  Parts:  Screws

• Tighten down screws (2).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Catalytic converter to holder
  M8 Replace screw.	tightening torque	19 Nm

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• 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: 24 34... Notes on mechatronics (GA8HP50Z/GA8HP51Z/GA8HP75Z/GA8H). Refer to 24 34 SHIFT VALVES, PARKING LOCK .

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• Slide the connector (1) on and turn it to lock.
• Tighten the transmission bolts (arrowed).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

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

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• Replace sealing rings.

  Parts:  Sealing rings

• Install hydraulic lines (1) on transmission.
• Position and tighten the screw (2).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

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

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• Install hydraulic lines (2) on transmission.
• Position and tighten the screw (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Transmission oil line on holder
  M6	Tightening torque	4 Nm

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• 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.
  Fig 2: Transfer Box With Front Propeller Shaft Screws Tightening Sequence

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• Tighten screws in the order (1) to (5).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  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

• Before the screw connection, a drop of Loctite 270 (2) must be placed on each thread on the end of respective screw (1).
  CONSUMABLE SPECIFICATIONS
  
  

  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 the screws (arrows).

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  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Prop shaft before the front axle differential
  Replace screws. Joining torque and angle of rotation must be observed without fail.	Joining torque	20 Nm
  	Angle of rotation	45°

• 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 TORQUE SPECIFICATIONS
  
  

  Ground strap to transmission or body
  M8	tightening torque	19 Nm

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• Install the transmission cross member (3).
• Tighten down screw (2).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Transmission cross member to rubber mounts
  M12	tightening torque	68 Nm

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• Tighten down screws (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  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 RIGHT REAR TENSION STRUT .
• Refer to CONNECTING ALL BATTERY GROUND LEADS .
• Refer to CHECKING/TOPPING UP THE OIL LEVEL IN THE AUTOMATIC TRANSMISSION .
• Refer to INSTALLING THE STIFFENING PLATE .
• Refer to INSTALLING FRONT UNDERBODY PROTECTION .
• Refer to INSTALLING UNDERBODY PROTECTION AT REAR .
• Refer to ENCODING/PROGRAMING CONTROL UNIT(S) .