24 00 033 Removing and installing automatic transmission (GA8HP45Z)

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Special tools required:

IMPORTANT: To prevent heavy damage to the engine block, the protruding thread of the transmission bolts absolutely must be checked for damage and corrosion before removal .
If there are signs of corrosion, the rust must be removed and the threads must be cleaned before removal .
Replace rusted, damaged screws.

Failure to comply with this instruction will result in serious damage to the engine block and transmission.

IMPORTANT:

Do not let skin come in contact with transmission oil and do not inhale transmission oil vapors.
Wear protective gloves.
Ensure adequate ventilation

IMPORTANT: After completion of work, CHECK TRANSMISSION OIL LEVEL .
Use only the approved TRANSMISSION OIL .
Failure to comply with this requirement will result in serious damage to the automatic transmission!

IMPORTANT: For vehicles with N54/N55 engine up to production date 09/2012, aluminum bolts for the for the securing of the transmission are also installed.
As of production date 09/2012, only steel bolts are installed for the securing of the transmission.

NOTE: Aluminum screws/bolts must be replaced each time they are released .
Aluminum screws/bolts are permitted with and without color coding (blue).
For reliable identification:
Aluminum screws/bolts are not magnetic .
Jointing torque and angle of rotation must be observed without fail (risk of damage) .
The aluminum bolts can be optionally replaced by steel bolts.

Necessary preliminary tasks:

Disconnect the battery . See 61 20 900 DISCONNECTING AND CONNECTING BATTERY EARTH LEAD or 61 20... INFORMATION ON AGM BATTERY
Release the left and right charge air hoses from the charge air cooler
Remove . See 51 47 491 REMOVING REFITTING/REPLACING REAR ENGINE UNDERCOVER or 51 47 490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION front underbody protection
Remove reinforcement plate Important installation notes are described in this job item
Remove PROPELLER SHAFT
Release MONITORING SENSOR on catalytic converter
Support engine with jack when removing gearbox

Remove upper part of cable duct (1).

Fig 1: Identifying Cable Duct Upper Part

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Unfasten ground strap (1).

Remove retaining plates (2).

Fig 2: Identifying Retaining Plates And Ground Strap

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Release cable (1) from holder (2).

Fig 3: Identifying Cable From Holder

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Release screw (1).

Disconnect hydraulic lines (2) to transmission oil cooler.

Tightening torque 17 22 1AZ .

Installation note:

Replace sealing rings.

Note installation position.

Fig 4: Identifying Hydraulic Lines And Screw

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IMPORTANT: Keep to installation sequence.
Failure to observe this sequence will result in leaks.

1. Lower hydraulic line.
2. Upper hydraulic line.

Release coolant hose (1) from holder (2) and lay to one side.

Fig 5: Identifying Coolant Hose From Holder

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Crank engine at vibration damper in direction of rotation until screw (1) is visible in recess.

Release all 6 bolts of torque converter with special tool 24 1 110 .

Installation note:

Replace converter screws. Remove any remaining adhesive residue from the thread.

Fig 6: Identifying Screw

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Tightening torque 24 40 1AZ .

Release nuts (1) and (2).

Tightening torque 18 20 1AZ .

Fig 7: Identifying Nuts

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Release screws (3),(4) and (9).

NOTE: Aluminum screws must be replaced.

Tightening torque 24 00 2AZ .

Fig 8: Transmission Housing Bolts Tightening/Loosening Sequence

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Prepare special tool (1) 24 4 161 (A) with shaped element (2) 24 4 166 as pictured.

Fig 9: Identifying Special Tool 24 4 161

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Insert special tool 24 4 160 into recess of transmission housing and clamp gently with screw (1).

Raise by turning screw (2) and clamp down.

Then tighten down screw (1).

Fig 10: Identifying Special Tool 24 4 160

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Unlock and disconnect connector (1) by turning.
Do not touch pins.
Release cable from brackets.
Insert special tool 24 2 390 in sealing sleeve.

Repair work is described in NOTES ON MECHATRONICS

IMPORTANT: Read and comply with important note.

Fig 11: Releasing Cable From Brackets

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Release screw (1) on left and right of axle.

Remove cover plate (2) on left and right of axle.

Remove bolt (3) on left and right of axle.

Tightening torque 31 10 1AZ .

Fig 12: Identifying Cover Plate, Bolt And Screw

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Screw on special tool 11 8 910 .

Fig 13: Screwing Special Tool 11 8 910

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Adjust distance (1) between cross bar and facing using nuts (2).

Nuts (2) must be screwed down in opposite direction after distance has been adjusted.

IMPORTANT: Distance:
N55 38.5 mm

Fig 14: Identifying Distance Between Cross Bar And Facing

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Supporting transmission:

Support transmission with special tools 23 4 050 , 00 2 030 .

Secure transmission to mounting with tensioning strap (1).

Tasks are described in GEARBOX HOLDER .

After completion of work, check transmission fluid level.

Fig 15: Supporting Transmission Using Special Tools 23 4 050

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Unscrew nut (1) and bolts (2).

Remove gearbox cross member (3).

Tightening torque 22 32 3/4AZ .

Fig 16: Identifying Gearbox Cross Member Bolts And Nut

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Release screws.

Remove exhaust system holder.

Installation note:

Observe screw fastening sequence without fail.

Tightening torque, steel screws 24 00 1AZ .

Fig 17: Transmission Housing Bolts Tightening/Loosening Sequence

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Aluminum screws must be replaced.

Tightening torque and angle of rotation, aluminum screws/bolts 24 00 2AZ (7, 8, 9, 10, 11).

Installation note:

Tighten down screws/bolts to specified torque.

Fig 18: Tightening Screws/Bolts

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Attach special tool 00 9 120 for angle of rotation with magnet 00 9 130 to vehicle underbody and screw down blue aluminum screws/bolts in accordance with angle of rotation.

Angle of rotation 24 00 2AZ .

Installation note:

Bore hole (1) of drive plate must be accessible from recess on engine oil sump. Check fitting sleeves (2...3) for correct seating.

Replace damaged fitting sleeves.

Fig 19: Identifying Sleeves Of Engine Oil Sump

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NOTE: Graphic representation similar.

Installation note:

Rotate torque converter until bore hole in torque converter is flush with bore hole in drive plate.

Flange automatic transmission to engine.