Transmission, removing: Removal

Disconnecting the battery lead

Disconnect the battery lead. See: Battery, disconnecting .

Removing engine compartment components

Fig 1: View Of Underhood Components

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Remove:

the engine stabilizer brace between the suspension turrets and the engine
the air cleaner (ACL) housing assembly with the intake pipe.

Unhook the turbocharger (TC) control valve from the air cleaner (ACL) housing.

Pull the air cleaner (ACL) housing out of its mountings.

Removing components from the transmission

Fig 2: Identifying Gear Selector Cable And Special Tool 999 7077

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Remove:

the gear selector cable. Use jimmy tool 9997077 to detach the ball joint for the cable from the lever
the cable mounting from the transmission
the oil line from the transmission. Plug the line and the connection on the transmission cover
unhook the mounting with the connector for the transmission from the bracket. Separate all the connectors.

Removing the mounting screws from the transmission

Fig 3: Identifying Screws

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Remove the bracket with the connectors for the heated oxygen sensors (HO2S) and the clamp for the cable harness from the transmission.

Remove:

the screws for the clamp securing the cable harness at the rear edge of the engine
the nut for the bracket for the cable harness and the engine coolant hose
the 3 screws for the transmission and engine and the 2 screws for the starter motor. Tie up the cable harness.

Removing the coolant hose from the passenger compartment heater

Fig 4: Identifying Passenger Compartment Coolant Hose & Clips

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Clamp the hoses with hose clips.

Place some paper under the inner hose connection to collect any spilled coolant.

Turn the quick-release connector (the inner of the 2 hoses) slightly in the direction of the arrow so that the lock opens. At the same time, pull the coolant hose straight out of the coolant pipe.

NOTE:

Tie the hose up to the engine so that it does not fall down and trap the hose connector between the firewall during installation.

Installing the lifting beams and lifting hooks on the engine lifting lugs

Fig 5: Identifying Fixture Kit, Lifting Beam And Lifting Hooks

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NOTE:

The front lifting beam must be equipped with fixture kit 9997070 as illustrated.

Position lifting beam 9995716 on the wheel arch and directly above the engine lifting eyelets on the left and right-hand sides.

Connect the lifting hooks 9995460 on the engine lifting lugs.

On the right-hand side of the engine, the hook must have a clearance of 10 mm . Also use lifting lug 9995185 on the left-hand side of the engine. Tighten to light contact on the left hand side.

Raise the car

Removing both the front wheels

Fig 6: Identifying Front Splash Guard

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Remove:

the front splash guard. See Sub-frame front, replacing
the splash guard under the engine.

Removing components from the sub-frame

Fig 7: Identifying Cable Duct

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Remove the screw for the cable duct. Unhook the cable duct from the sub-frame.

For cars with fuel powered parking heaters:

Remove the 2 screws for the heater.

Unhook the heater from the mounting. Leaving it hanging in its upper mounting.

Detach the fuel line for the heater from the holders on the sub-frame.

Removing the cross members from the body

Fig 8: Identifying Front Crossmember And Bolts

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Remove:

the clamp for the heated oxygen sensor (HO2S) cable and the screws for the front member
the brake pipe from the holders on the member.

Turn the member to the side so that the exhaust pipe is exposed.

Removing the screws and nuts for the engine pad, engine stabilizer brace and steering gear

Fig 9: Identifying Screws

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Remove:

the screw for the engine pad/steering gear
the screw for the front engine pad
the screws for the engine stabilizer brace.

Measuring the position of the tie rod in the steering gear

Fig 10: Identifying Length Of Track Rod In Relation To Steering Gear Housing

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Set the front wheels to the straight ahead position.

Lock the steering wheel. On one side, measure the length of the tie rod in relation to the steering gear housing.

Note the measurement.

Disconnecting the steering gear

Fig 11: Identifying Steering Wheel Shaft Joint

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Remove the screw for the joint between the steering gear and the steering shaft.

Press up the joint from the steering gear.

Removing front suspension components (both sides)

Fig 12: Identifying Front Suspension Components

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Remove:

the soundproofing over the drive shaft (applies to certain versions)
the screw for the drive shaft. Counterhold using a screwdriver in the brake disc vents. Tap in the end of the drive shaft approximately 20 mm into the wheel hub
the link from the anti-roll bar. Counterhold using a Torx wrench in the ball joint pinion to prevent the boot from turning. (Applies to the left-hand side only.)
the nut for the ball joint / link arm. Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut.

Disconnecting the ball joint pinion from the control arm (both sides)

Fig 13: Identifying Ball Joint Pinion, Control Arm And Special Tool 9997062

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Use tool 9997062 . Install cap nut 9997062 for the ball joint pinion. Tighten the nut to the control arm. Then slacken off 1 to 2 turns so that there is clearance between the cap nut and the control arm.

Position puller 9997062 on the control arm and detach the ball joint from the control arm.

Remove the tools.

Removing fender liner components (both sides)

Fig 14: Identifying Support Plate And Nuts

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Slacken off the 2 nuts for the fender liner and the support plate on both sides so that the fender liner can be folded out.

Removing the screws for the sub-frame support plates (both sides)

Fig 15: Identifying Screws And Sub-Frame Support Plates

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Remove the screws for the sub-frame support plates in the body (both sides).

Position mobile jack 9985972 with universal plate 9995972 , so that the plate is in light contact under the right-hand side of the sub-frame.

Slacken off the screws for the sub-frame on the right hand side. Ensure that the nuts are still secured by at least 5 threads.

Remove the jack.

Unhook the control arm from the ball joint. Install protective sleeve 9995562 . Hold the sleeve in place using the nut for the ball joint.

Work out the spring strut. Detach the drive shaft from the wheel hub. Do not damage the boot. Hold the spring strut to one side using a retaining strap for more space when removing the drive shaft.

Removing the right drive shaft

Fig 16: Identifying Drive Shaft Support Bearing Cap

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Remove:

the support bearing cap for the drive shaft
the drive shaft by pulling it straight out of the transmission.

Removing the collision protection system over the steering gear

Fig 17: Identifying Collision Protection Over Steering Gear & Screws

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NOTE:

Only applies to right-hand drive cars.

Remove the 2 screws for the collision protection system.

Leave the collision protection system in place on the steering gear.

Lowering the sub-frame

Fig 18: Identifying Mobile Jack & Sub-Frame

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NOTE:

Applies only to right-hand drive cars.

Position the mobile jack lightly applied under the left side of the sub-frame. Remove the sub-frame screws.

NOTE:

Ensure the following when lowering the sub-frame:

that the brake pipe does not catch in the bracket for the exhaust pipe mounting
that the ball joint pinion releases from the control arm.

Remove the mobile jack and let the frame hang loose.

Removing the drive shaft from the wheel hub

Fig 19: Identifying Drive Shaft And Wheel Hub

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Work out the spring strut. Detach the drive shaft from the wheel hub. Hold the spring strut to one side using a retaining strap to obtain more space when removing the transmission.

Removing the drive shaft from the transmission

Fig 20: Identifying Drive Shaft At Gearbox & Tool 999 5681

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Remove the drive shaft from the transmission. Use jimmy bar 9995681 .

Removing bevel gear

Fig 21: Identifying Bevel Gear And Screws

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Remove the angle gear screws, 5. Pull the angle gear straight out from the gearbox.

Hang the bevel gear from, e.g., an oil pipe for the turbocharger or similar.

Fig 22: Identifying Bevel Gear Hung Up With Cable

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Removing the rear engine mounting

Fig 23: Identifying Rear Engine Mounting

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Remove:

the 3 x screws
the mounting and the engine pad.

Removing the screws from the torque converter

Fig 24: Identifying Torque Converter Screws

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Remove the 6 screws for the torque converter. Turn the engine with a ratchet and socket. Fold out the right-hand fender liner so that the crankshaft nut can be accessed.

Use a Torx TX50 socket on the torque converter screws.

Removing the oil pipe from the transmission

Fig 25: Identifying Oil Pipe

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Position a container under the pipe terminal.

Remove:

the 2 screws holding the pipe. Disconnect the pipe from the transmission. Install sealing plugs in the pipe and transmission. Carefully fold the hose out of the way
the ground lead from the transmission.

Lowering the engine and the transmission

Fig 26: Identifying Free Threads On Lifting Hook

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Lower the engine and transmission on the left-hand side. Use the hook.

Check that no hoses or cables are being stretched or trapped when the engine is lowered.

Lower the engine so that 90-100 mm of the free threads on the lifting hook can be seen.

Raise the car.

Installing the fixture on the mobile jack and transmission

Fig 27: Identifying Special Tools Fixture 999 5463, 999 5972 And Mobile Jack 998 5972

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Raise the car.

Install fixture 9995463 on fixture 9995972 . Use the fixture and plate together with mobile jack 9985972 . Align support plate 999 5463-2 against the fixture and the transmission.

NOTE:

The support plate is installed on the inside of the fixture mounting lug (see the illustration). Tighten the fixture with the two torque rod screws. Apply the mobile jack lightly against the transmission.

Removing all the screws for the transmission and engine

Fig 28: Identifying Gearbox And Engine Screws

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Remove the remaining 7 screws for the transmission and engine.

Removing the transmission

Fig 29: Identifying Height And Angle Adjusted With Mobile Jack And Gearbox Fixture

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Ensure that the transmission is taken straight out in relation to the engine.

Ensure that the torque converter is removed with the transmission and does not slide off the stator shaft.

Press a screwdriver through one of the screw holes in the carrier plate.

NOTE:

Do not pry toward the carrier plate rim for the flywheel sensor.

NOTE:

Lower the transmission slightly when it is being removed so that it will pass the side member.

Remove the transmission.