Installing automatic transmission (all-wheel drive vehicle) (GA8HP75Z)

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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).

Checking installation position of torque converter

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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 positions of the torque converter may lead to damage to the impeller driver .

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

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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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.

Before installing the automatic transmission, horizontally align it to the engine.

Checking lining sleeves

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

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Flange-mount transmission

Transmission flange-mount.
Rotate torque converter until bore in torque converter is flush with bore in drive plate.

Join and tighten the transmission bolts (arrows).

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TIGHTENING TORQUE SPECIFICATIONS

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

Remove the special tool from the torque converter

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

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Tighten converter bolt

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Replace screws.

Parts: Screws

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

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

Turn the torque converter until the elongated hole (1) is visible in the opening.
Tighten down screw.

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.

Fig 1: Torque Converter Screws Tightening Sequence

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TIGHTENING TORQUE SPECIFICATIONS

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

Install the sealing cap (1).

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Lock the connector with the sealing sleeve

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/GA8)

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

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Notes on mechatronics

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 automatic transmission after removal of the mechatronics .
Serious damage to the automatic transmission due to non-compliance with the following tasks:

Load specific data status with the diagnostic system.
Use only approved transmission oil.
After completion of repair work, check the transmission oil level.

NOTE: RISK OF DAMAGE
Electrostatic discharge .
Damage to or destruction of electrical components .

Leave the electrical components in their original packaging until they are being installed. Only use the original packaging for returning the product. Always package removed components straight away.
Read and comply with user information on using the associated special tool 12 7 060.
Only tap the housings of electrical components. Do not tap pins or multi-pin connectors directly.
Wear electrically conductive clothing and antistatic shoes (with ESD symbol).
For additional information see: 61 35... NOTES ON ESD (ELECTROSTATIC DISCHARGE) PROTECTION .

Fix hydraulic lines

Replace sealing rings.

Parts: Sealing ring

Install hydraulic lines (2) on transmission.
Position and tighten the screw (1).

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TIGHTENING TORQUE SPECIFICATIONS

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

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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Connecting the connector with the VTG control unit

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

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Install the ground strap

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

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TIGHTENING TORQUE SPECIFICATIONS

Ground strap to transmission or body
M8	tightening torque	19 Nm

Installing transmission cross member .

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

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TIGHTENING TORQUE SPECIFICATIONS

Transmission cross member to body
M8	tightening torque	19 Nm

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

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Securing the lines

Secure the lines (3).
Replace screws (1) and (2).
Parts: Screws
Tighten down screw (1).
Tighten down screw (2).

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TIGHTENING TORQUE SPECIFICATIONS

Standard screw connection M5
M5	Tightening Torque	5 Nm

Install the heat shield (2).
Replace screws (1).

Parts: Screws

Tighten down screws (1).

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TIGHTENING TORQUE SPECIFICATIONS

Standard screw connection M6
M6	Tightening torque	8 Nm

Remove the transmission jack

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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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 THE HEAT SHIELDS .
Refer to INSTALLING THE CATALYTIC CONVERTER NEAR ENGINE, BOTTOM AT BANK 2 .
Refer to INSTALLING THE CATALYTIC CONVERTER NEAR ENGINE, BOTTOM AT BANK 1 .
Refer to INSTALLING HEAT SHIELD, TOP .

Installing conduit on bank 2

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Clip the wiring harness (2) into the clamps (1).

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Position the wiring harness.

Tighten down screws (1).

TIGHTENING TORQUES

Cable duct
M6x16 screw	Tightening torque	10Nm

Installing cable duct at cylinder bank 1.

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Position the conduit (2).
Tighten the screws (1).

TIGHTENING TORQUES

Cable duct
M6x16 screw	Tightening torque	10Nm

Refer to INSTALLING THE OXYGEN SENSOR MONITOR OF CYLINDER BANK 1 .
Refer to CHECKING THE POSITION OF THE HEAT SHIELD .
Refer to INSTALLING THE EXPANSION TANK FOR THE CHARGE AIR COOLER .
Refer to INSTALLING COOLANT EXPANSION TANK .
Refer to INSTALLING HOLDER OF THE DME CONTROL UNIT FOR CYLINDERS 5 TO 8 .
Refer to INSTALLING THE LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 5 TO 8 .
Refer to INSTALLING THE OXYGEN SENSOR MONITOR OF CYLINDER BANK 2 .
Refer to INSTALLING THE LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 1 TO 4 .
Refer to INSTALLING ACOUSTIC COVER .
Refer to INSTALLING THE COVER PANEL OF THE SLAVE DME CONTROL UNIT .
Installing the cover panel of the master DME control unit.

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- Position the cover of the master DME control unit (1).
- Engage the cover panel of the master DME control unit (1) downwards with the clamps (2) and the guide pins (3) in the carrier plate of the DME.
Refer to INSTALLING THE CENTER COWL UPPER PART .
Refer to INSTALLING TENSION STRUT ON SHOCK TOWER .
Refer to INSTALLING WINDSHIELD PANEL COVER .
Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
Installing the rear right engine compartment cover.

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Remove the battery cover .

NOTE: The following step(s) must be performed if the listed component(s) is/are installed.
- Remove the special tool 2 452 007 from the battery.
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- Install the cover (2).
- Lock the lock (1).
Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT ON THE REAR LEFT .
Refer to INSTALLING EXHAUST SYSTEM .

Installing the rear tunnel connecting support.

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Position the connecting support (3) on the rear of the tunnel.

Tighten the screws (1).

TIGHTENING TORQUES

Rear connecting support tunnel to body
M8x30	Snug torque Angle of rotation	28Nm 90°

Tighten screws (2).

TIGHTENING TORQUES

Undershield
Hexagon screw	tightening torque	2.6Nm
Plastic nut	tightening torque	2.6Nm

Refer to INSTALLING THE REINFORCEMENT STRUT .
Refer to INSTALLING UNDERSHIELD ON THE FUEL TANK ON THE RIGHT .
Refer to INSTALLING THE UNDERSHIELD ON THE LEFT FUEL TANK .
Refer to CONNECTING BATTERY GROUND LEAD .
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 THE REAR DIFFUSER .