Mounting Automatic Transmission

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WARNING: Danger of objects or loads falling down

Risk of squashing or crushing

→ Secure components to prevent them from falling down.

Information

Screws which are tightened with a torque angle must be replaced with new ones .

Information

A second fitter is required .
Replace converter screws .

Information

The tightening specifications for the basic engine are stored centrally (→ 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS ).

Tightening Torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

Information

The sealing rings at the ends of the ATF lines on the transmission and cooler sides must be replaced before installation .

Fix engine to the crankshaft with special tool Fixing Pins 9595 .

Fig 1: Disconnecting Crankshaft
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NOTE:
Torque converter installed incorrectly
- Risk of damage to transmission and torque converter
→ Always observe installation dimension

→ When securing the transmission, check that the torque converter can turn freely and is not jammed.

→ Do not use force when screwing the engine and transmission together
CAUTION:
ATF pump can be damaged if not installed correctly.
- Risk of shearing off drivers on ATF pump pinion
→ Precisely align cut-outs on the converter hub with the drivers on the ATF pump pinion

→ Install the converter slowly and carefully
Before Installing The Transmission, Make Sure That The Torque Converter Is Inserted Correctly In The Transmission .
Check installation dimension -a- .

Fig 2: Checking Installation Dimension For Torque Converter
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Insert special tool Centering Pin 9689 in converter.

Fig 3: Identifying Torque Converter Centering Pin
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Lift the transmission using the workshop crane and move it into the installation position with respect to the engine.
Put engine and transmission together.
The dowel sleeves on the engine must slip perfectly into the bores on the transmission bell housing.
Fit the transmission screws with the holders for the primary catalytic converters. → INSTALLING AUTOMATIC TRANSMISSION - section on "Installing"

Fig 4: Identifying Transmission Screws
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Remove special tool Centering Pin 9689 and fit torque converter screws. For Tightening Torques, see → MOUNTING AUTOMATIC TRANSMISSION - section on "Mounting", → INSTALLING TORQUE CONVERTER - section on "Installing"
Fit fastening screws -1, 2- for the rear cross member -3- to → Initial Tightening: 50 Nm (37 ft. lb.) on the transmission -4- and tighten to → Final Tightening: 90° .

Fig 5: Identifying Rear Transmission Cross Member
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Remove workshop crane from the engine.
Screw in new converter screws.
Place screw on special tool Bit Insert 9688 and screw in screw.

Fig 6: Opening For Converter Screw On Engine
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Position bit snap-on head and special tool Insert 9687 and screw in screw, but do not tighten.
Turn crankshaft clockwise with special tool Socket Wrench Insert 9714 .
Insert special tool Locating Pins 9595 into the front bore on the converter bell housing -arrow- and hold in place with light pressure until it engages when the crankshaft is turned. This sets the position for the next screw.

Fig 7: Locating Converter Screws
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Complete the steps described above for the other five screws.
Remove special tool Fixing Pins 9595 before tightening the converter screws to the specified torque. → Tightening Torque: 85 Nm (63 ft. lb.)
Insert plug for converter assembly opening. To do this, moisten the groove on the plug with water.

Fig 8: Plug Used To Seal Converter Opening
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Starting at the cut-out in the engine block -1- , press in the plug all the way round from position -2-3- .

Fig 9: Locating Plug
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Check the position of the plug -2- using an inspection mirror -1- . When doing this, make sure that the sealing lip -3- makes contact all the way round.

Fig 10: Identifying Installation Position Of Plug
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Secure holder -1- for ATF lines to the front of the transmission.
Screw in and tighten fastening screw to → Tightening Torque: 23 Nm (17 ft. lb.) .

Fig 11: Identifying Holder For ATF Lines At Front Of Transmission
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Clip ATF line into the holder -A- .
Position the front ATF line -2- on the ATF heat exchanger -3- .
Ensure that the lines are seated correctly.

Fig 12: Locating ATF Lines At Top
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Fit fastening screws -1- to → Tightening Torque: 8 Nm (6 ft. lb.) .
Position ATF lines -2- with holder in the transmission -3- .
Ensure that the lines are seated correctly.

Fig 13: Detaching ATF Lines At Bottom
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Fit fastening screw -1- to → Tightening Torque: 20 Nm (15 ft. lb.) .
Fit fastening screws -1- of the heat shield -2- to the automatic transmission -3- to → Tightening Torque: 15 Nm (11 ft. lb.) .

Fig 14: Identifying Heat Shield For Automatic Transmission
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Push the vacuum hose -1- onto the T-piece -2- .
Clip vacuum line -3- into the holder -4- .

Fig 15: Identifying Vacuum Supply Hose
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Connect the coolant hose -2- for the ATF heat exchanger on the right to the connection piece and fit the clamp -1- .

Fig 16: Identifying Right Coolant Line
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Clip the hose -1- for the transmission vent into the holder -2- .

Fig 17: Identifying Transmission Vent Hose
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Connect the electric plug connection of the crankshaft pulse sender at the bottom of the transmission and lock it.
Secure the wire harness with a tie-wrap if necessary.

Fig 18: Locating Plug Connection For Crankshaft Pulse Sender
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Fit the front cardan shaft. → INSTALLING FRONT CARDAN SHAFT - section on "Installing"
Place the catalytic converters in position on the engine and transmission assembly.
1. 33.1. Position the fastening nuts -1- of the primary catalytic converters and fit them.
  
  Fig 19: Identifying Primary Catalytic Converters
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2. 33.2. Fit the fastening screws -1- of the primary catalytic converters -3- at the gear supports -2- .
  
  Fig 20: Identifying Holder For Primary Catalytic Converter
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3. 33.3. Fit the fastening screws -1- of the rear catalytic converters to the holders -2- at the transmission.
  
  Fig 21: Identifying Holder For Catalytic Converters
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Clip the wire harness -1- for the oxygen sensor on the right into the holders -2- on the engine.

Fig 22: Identifying Wire Harness For Right Oxygen Sensor
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Clip the wire harness -1- for the oxygen sensor on the left at the cylinder head cover into the holder -2- .

Fig 23: Identifying Wire Harness For Left Oxygen Sensor
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Place the holder -2- for the coolant lines in position on the transmission and fit the fastening screw -1- .

Fig 24: Identifying Holder For Coolant Lines
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Connect the coolant hoses -2- on the left of the transmission and fit the clamps -1- .

Fig 25: Identifying Coolant Hoses On Left
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