Installing the automatic transmission (GA8HP75HZ)

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

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

Tighten down screw (1).

TIGHTENING TORQUE SPECIFICATION

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

Install the transfer box with the front prop 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 (arrows) in the sequence (1) to (5).

TIGHTENING TORQUE SPECIFICATION

Transfer box to automatic transmission
M10	tightening torque	43 Nm

Fig 1: Transfer Box Screws Tightening Sequence

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Before installing the prop shaft on the front axle transmission, remove and clean all 4 threads (1) in the front axle transmission flange from possible residues and contamination.

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Replace screws.
Parts: Screws
Coat each thread at the end of the respective screw (1) with Loctite 270 (2) before screwing it on.
CONSUMABLE DESCRIPTION

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.

Position the front prop shaft and tighten the screws (arrows).

TIGHTENING TORQUE 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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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).

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Connect connectors (1) and lock.

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Insert and install the holder (4).
Replace screws (3).
Parts: Screws
Hand-tighten the screws (3).
Replace the screw (2).
Parts: Screw

Tighten down screw (2).

TIGHTENING TORQUE SPECIFICATION

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

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Replace nut (1).
Parts: Nut

Tighten nut (1).

TIGHTENING TORQUE SPECIFICATION

Catalytic converter to holder
M8 Replace nut.	Tightening torque	19 Nm

Tighten screws in the sequence (1) to (9).

TIGHTENING TORQUE SPECIFICATION

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

Fig 2: 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 SPECIFICATION

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 SPECIFICATION

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

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Position holder (2).
Insert high-voltage connector (3).
Replace nut (1).
Parts: Nut

Tighten nut (1).

TIGHTENING TORQUE SPECIFICATION

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

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Unlock the clamps (1).
Remove the special tool 5 A29 F40 from the 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 SPECIFICATION

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

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Install holder (3).
Replace the screws (1) and nut (2).
Parts: Bolts, nut

Tighten the screws (1) and nut (2).

TIGHTENING TORQUE SPECIFICATION

Front pipe/front silencer/gasoline particulate filter to the transmission holder
M8 Replace nut.	tightening torque	19 Nm

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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 the screw (1).
Parts: Screw

Tighten down screw (1).

TIGHTENING TORQUE SPECIFICATION

Ground strap to transmission or body
M8	tightening torque	19 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 SPECIFICATION

Ground strap to transmission or body
M8	tightening torque	19 Nm

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

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

Tighten down screws (1).

TIGHTENING TORQUE SPECIFICATION

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 SPECIFICATION

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