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

CAUTION: Materials harmful to health.
Contact with fluids harmful to health!

Note and follow safety instructions on containers.
Conduct all work in appropriate personal protective equipment only.

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: RISK OF DAMAGE
Damage to engine block.
Serious damage to the engine block and transmission due to damaged and corroded screws.

It is imperative that protruding threads of the transmission bolts are checked for corrosion and damage prior to removal.
It is imperative that all rust is removed from corroded threads and that they are cleaned prior to removal.
Replace rusted and damaged bolts.

Check the fitting sleeves (1) for correct seating and damage and replace if necessary.

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Checking installation position of torque converter

NOTE: RISK OF DAMAGE
Damage to the automatic transmission/impeller.
When disconnecting the engine and transmission, the torque converter can become loose! Failure to observe the correct installation position of the torque converter can lead to damage to the driver of the impeller.

Make sure that the torque converter is in the correct installation position before installing the automatic transmission.

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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
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 (1).
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

Loctite 270 high-strength thread lock

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.	Snug torque	25 Nm
	Angle of rotation	45°

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Flange-mount the transmission on the transfer box (VTG).
Turn the torque converter until the bore of the torque converter is aligned with the bore of the drive plate.
Fit the transmission bolts (1) to (9) and apply lightly.

Fig 1: Transmission Bolts Tightening Sequence
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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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Slide connector (1) in the arrow direction and lock it by turning it.

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

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Install the sealing cap (1).

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Replace screws (1).
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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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

Connect the connector (1) to the transfer box control unit for the longitudinal torque distribution (2).

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Install the ground strap (2).
Tighten down screw (1).

TIGHTENING TORQUES SPECIFICATION

Grounding strap/grounding cable to transmission/body
M8	Tightening torque	19 Nm

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Install holder (3).
Tighten the screws (1).

TIGHTENING TORQUES SPECIFICATION

Catalytic converter holder to automatic transmission switch
M8X20	Tightening torque	19 Nm

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Replace the nuts (2).
Parts: Nuts
Tighten nuts (2).

TIGHTENING TORQUES SPECIFICATION

Holder for catalytic converter, cylinders 4 to 6
M8 Replace nuts.	tightening torque	19 Nm

Insert the positive battery cable (4).

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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Replace screws (1).
Parts: Screws
Tighten the screws (1) on the transmission bearing support (2).

TIGHTENING TORQUES SPECIFICATION

Transmission bearing support to body
M8	Tightening torque	19 Nm

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Install the transmission cross member (2).
Tighten the screws (1).

TIGHTENING TORQUES SPECIFICATION

Transmission cross member to body
M8	Tightening torque	19 Nm

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Release the luggage strap (1) from the transmission.
Remove the special tools 0 495 498 (23 4 050) and 2 219 012 from the transmission.

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Install the retaining plate (2).
Tighten nuts (1).

TIGHTENING TORQUES SPECIFICATION

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

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Follow-up work

Refer to INSTALLING STARTER MOTOR .
Refer to FASTENING THE PROP SHAFT (PARTIALLY REMOVED) .
Refer to INSTALLING THE HEAT SHIELDS .
Refer to INSTALLING EXHAUST SYSTEM .
Refer to INSTALLING CENTER STIFFENING PLATE .
Refer to IF INSTALLED: INSTALLING THE RIGHT AND LEFT TORSION STRUTS .
Refer to FASTENING THE CHARGE AIR CROSSING .
Refer to INSTALLING FAN COWL .
Refer to INSTALLING THE WHEEL ARCH COVER ON THE FRONT LEFT AND BOTTOM RIGHT .
Refer to INSTALLING TANK COVER ON LEFT AND RIGHT .
Refer to ACTIVATING VEHICLE-SPECIFIC HIGH-VOLTAGE OR LOW-VOLTAGE VEHICLE ELECTRICAL SYSTEM .
Refer to INSTALLING UNDERBODY PROTECTION AT REAR .
Refer to INSTALLING THE CENTER UNDERBODY PROTECTION .
Refer to INSTALLING FRONT UNDERBODY PROTECTION .
Refer to INSTALLING THE FRONT SECTION OF THE FRONT WHEEL ARCH COVER .
Refer to INSTALLING THE COVER OF THE STEERING ASSEMBLY .
Refer to PARTIALLY INSTALLING THE FRONT WHEEL ARCH TRIM .
Refer to ATTACHING THE FRONT LEFT WHEEL .
Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
Refer to INSTALLING FRONT CROSS CONNECTION .
Refer to INSTALLING FRONT-END STRUT ON LEFT AND RIGHT .
Refer to INSTALLING INTAKE FILTER HOUSING .
Refer to INSTALLING THE STRUT BRACE .
Refer to INSTALLING MOUNT OF HOOD SEAL ON THE LEFT AND RIGHT .
Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT AT TOP LEFT AND RIGHT .
Refer to INSTALLING THE SEAL FOR THE HOOD GASKET LEFT AND RIGHT .
Refer to INSTALLING THE COVER PANEL OF THE ENGINE COMPARTMENT ON THE REAR LEFT AND RIGHT .