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: TECHNICAL INFORMATION
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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Replace the O-ring (1) 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 marks (2) and (4) .
Slide the front prop shaft (1) up to the stop into the output flange (3) of the 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 special tool 0 494 213 (24 2 390) from sealing sleeve (1) in the arrow direction.

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Slide connector (1) in the arrow direction and lock it by turning it.

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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	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	19 Nm

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Tighten the screws in the sequence (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	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	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	8 Nm

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Position the high-voltage cable (1) on the holder (3) in the arrow direction.
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	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.

TIGHTENING TORQUE SPECIFICATIONS

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

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DANGER

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 positive battery cable (2) into 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

Follow-up work

Refer to INSTALLING FRONT PROPELLER SHAFT AT THE FRONT AXLE TRANSMISSION .
Refer to FASTENING THE PROP SHAFT (PARTIALLY REMOVED) .
Refer to INSTALLING TRANSMISSION CROSS MEMBER .
Refer to INSTALLING THE HEAT SHIELDS .
Refer to INSTALLING CATALYTIC CONVERTER .
Refer to INSTALLING THE COMPLETE EXHAUST SYSTEM .
Refer to INSTALLING THE REAR DIFFUSER .
Refer to IF INSTALLED: INSTALLING THE TORSION STRUT ON THE RIGHT, AND ON THE LEFT WHERE REQUIRED .
Refer to INSTALLING THE REAR AXLE COVER .
Refer to INSTALLING THE CONNECTING SUPPORTS ON THE TUNNEL .
Refer to INSTALLING THE OXYGEN SENSOR MONITOR .
Refer to INSTALLING LAMBDA OXYGEN SENSOR .
Refer to INSTALLING THE HOLDER OF THE POSITIVE BATTERY CABLE .
Refer to INSTALLING THE RESONATOR WITH THE TOP CLEAN AIR PIPE .
Refer to INSTALLING INTAKE SILENCER HOUSING .
Refer to CONNECTING ALL BATTERY GROUND LEADS .
Refer to CHECKING/TOPPING UP THE OIL LEVEL IN THE AUTOMATIC TRANSMISSION .
Refer to INSTALLING THE UNDERBODY PLANKING OF THE TRANSMISSION ON THE SIDE .
Refer to INSTALLING REAR UNDERBODY PROTECTION .
Refer to INSTALLING THE STIFFENING PLATE .
Refer to INSTALLING FRONT STIFFENING PLATE .
Refer to INSTALLING THE UNDERBODY PROTECTION OF THE STEERING GEAR OR THE FRONT THRUST FIELD .
Refer to INSTALLING ACOUSTIC COVER AT REAR .
Refer to INSTALLING THE FRONT HOOD SEAL AT THE REAR .
Refer to INSTALLING ACOUSTIC COVER .
Refer to ACTIVATING HIGH-VOLTAGE SYSTEM .
Refer to INSTALLING FLAP IN RIGHT LUGGAGE COMPARTMENT TRIM PANEL .