Transmission, Installing

Special tools:

9512050

NOTE:

As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

NOTE:

For tightening torques see: Tightening Torque , Tightening Torque , Tightening Torque and Tightening Torque .

Installing the gearbox

Before installing the transmission it is very important that the checks and cleaning have been carried out. See Transmission, Preparations Before Installing .

Adjusting the position of the engine and gearbox

Fig 1: Adjusting Height & Angle Using Mobile Jack And Gearbox Fixture

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Adjust height and angle with the mobile jack and the gearbox fixture.

Locate the gearbox on the engine.

Ensure that the gearbox goes straight in, in relation to the engine, and that the guide sleeves and guide pin for the starter motor align in the guide holes on the gearbox.

Installing and tightening the screws for the gearbox

Fig 2: Identifying Transmission And Engine Screws

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Install the 7 x M10 screws for the transmission/engine.

First tighten alternately and crosswise to light contact.

At the same time, check that the whole of the gearbox is in contact with the engine.

Then install the screws to light contact. Tighten.

Remove the fixture from the gearbox.

Installing the torque converter screws

Fig 3: Identifying Torque Converter Screws

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NOTE:

Use new screws, Torx TX 50

Align the torque converter against the carrier plate. Do this by turning the engine with the nut for the crankshaft pulley and turning the torque converter.

Install all 6 x screws loosely. Insert the screws as far as the screw heads sit almost against the carrier plate. Tighten. See: Summary of tightening torques for specific components .

NOTE:

Remove the socket wrench from the crankshaft.

Lifting the engine and gearbox to the horizontal position

Fig 4: 999 5716 And 999 5460 Installed On Engine

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Raise the engine/transmission to the horizontal position.

Raise the vehicle.

Installing the rear engine mounting

Fig 5: Identifying Rear Engine Mounting

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Install:

the rear engine mounting on the gearbox
the 3 x M10 screws for the engine mounting. Loosely tighten the screws for the engine pad/steering gear.

Fig 6: Charge Air Pipe

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Install the charge air pipe on the engine.

Installing the lower oil pipe on the gearbox

Fig 7: Gearbox Oil Pipe And Screws

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Use a new O-ring.

Install:

the oil pipe. Tighten the lower screw, 1 x M6
the upper screw (oil pipe/dipstick pipe). Tighten. See: Summary of tightening torques for specific components .
a tie strap for the cable harness for the oil pipe
the ground lead to the engine.

Installing the bevel gear

Fig 8: Angle Gear Screws

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Only applies to vehicles with four-wheel drive AWD.

NOTE:

Before installing the angle gear the splined joint between the gearbox and the angle gear must be lubricated with grease in accordance with: Splines greasing .

Check that the contact surfaces on the gearbox and the angle gear are clean.

Install the bevel gear. Use new screws. Tighten the screws alternately to light contact . Tightening torque .

Installing the left drive shaft on the gearbox and the stub axle

Fig 9: Constant Velocity Joint Housing At Transmission

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NOTE:

Make sure that the seal is fitted on the drive shaft.

Fit the drive shaft joint sealing ring in accordance with: Seal CV joint housing, replacing .

Press in the constant velocity joint housing so that the lock ring goes in its groove in the transmission.

Check by pulling the constant velocity joint.

Locate the drive shaft in the wheel hub. Install a new screw loosely in the drive shaft.

Installing the subframe on the bodywork

Fig 10: Identifying Sub-Frame And Screws

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NOTE:

Use new screws. Lubricate the screw threads.

Lift up the subframe until it is about 150 mm from the side member.

Secure the power steering pipe at the front edge of the upper side of the subframe using the rubber covered clamp. Install the screw. Finger tighten.

NOTE:

When the subframe is raised, ensure that the screws for the steering gear locate in the frame. Ensure that the ball joint pinion for the spring strut is aligned in the control arm.

Install:

the new screws and the support bracket at the rear edge
the bracket screws loosely.

Tighten the subframe screws to light contact.

Remove the mobile jack.

Installing the right drive shaft on the gearbox, stub axle and control arm

Fig 11: Bearing Cap And Drive Shaft Support Bearing

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Fit the bearing cap to the drive shaft support bearing, 2 x M8.

Tighten.

NOTE:

Ensure that the seal is in place on the drive shaft. Install the sealing ring for the constant velocity joint housing. See Seal CV Joint Housing, Replacing .

Locate the drive shaft in the wheel hub. Install a new screw loosely in the drive shaft.

Press down the control arm. Locate the spring strut in the ball joint pinion for the spring strut in the control arm.

Position the mobile jack lightly applied under the right side of the subframe.

Remove both the subframe screws.

Install:

new screws in the subframe
NOTE:
Lubricate the screw threads.
the screws loosely in the rear edge of the support plate.

Tighten the subframe screws to light contact.

Remove the mobile jack.

Tightening the subframe screws (both sides)

Fig 12: Identifying Sub-Frame And Screws

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First tighten the frame's screws on the left side, then on the right acc. to: TIGHTENING TORQUE (B5204T5; B5254T4) .

Use angle gauge 9512050 .

Then tighten the 4 x M10 screws for the frame brackets.

Fitting the screws for engine pads and the torque rod bracket in the gearbox

Fig 13: Engine Pads And The Torque Rod Bracket Screws

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Install:

the screws, M10, to the front and rear engine pads. Tighten
the torque rod mounting on the gearbox.

NOTE:

Use new screws.

Tighten according to: Tightening Torque

Installing the steering wheel shaft joint

Fig 14: Identifying Steering Wheel Shaft Joint

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Align the steering wheel shaft joint on the steering gear.

Install a new steering wheel shaft screw. Tighten. See: Tightening Torque .

Connect the cable to the stepper motor/solenoid.

Check the tie rod position. See: Measuring The Position Of The Tie Rod In The Steering Gear

Installing the collision protection system over the steering gear

Fig 15: Collision Protection Over Steering Gear

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Applies only to right-hand drive vehicles.

Install both the M12 screws. Tighten.

Installing the cross member

Fig 16: Cross Members

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Install:

the front cross member and the brake pipe in their holders
the other two cross members.

Tighten all the screws.

Installing and tightening the front suspension components

Fig 17: Front Suspension Components

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Install the nut for the ball joint pinion. Counterhold the ball joint pinion while tightening so that the ball joint boot cannot turn. Use a new M12 nut.

Tighten according to: Summary Of Tightening Torques For Specific Components

Tighten the drive shaft screw. Use a new screw.

Counterhold the brake disc. Use a screwdriver. Tighten. See: Summary Of Tightening Torques For Specific Components

Use angle gauge 9512050 .

Install:

the link for the anti-roll bar. Counterhold the ball joint pinion while tightening so that the ball joint boot cannot turn. Use a new lock nut. Tighten. See: Summary Of Tightening Torques For Specific Components
The ABS line in the mounting in the spring strut
the wing liner with support plate and nuts.

Installing the wiring duct

Fig 18: Fuel Line For Heater And Sub-Frame

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Install:

the cable duct for the subframe
the ground cable to the subframe
the additional heater / parking heater on the mounting in the subframe and the fuel line to the mountings
the front splash guard
the protective cover under the engine
the wheels. See Installing Wheels .

Removing the lifting beam

Fig 19: Identifying Lifting Beam And Lifting Hook Installed On Engine Lifting Eyelet

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Lower the vehicle.

Remove the lifting beams and lifting hooks from the engine.

Installing the remaining screws for the gearbox and starter motor

Fig 20: Gearbox Mounting Screws

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Install:

the 4 x screws for the transmission/starter motor. Tighten to 50 Nm
the screws for the starter motor. Tighten to 50 Nm .

Fig 21: Ground Lead, Coolant Hose, Charge Air Pipe And Clamps

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Install:

the hose and the clamp for the charge air pipe which are under the engine
the ground lead mounting on the subframe
the engine coolant hose to the pipe at the rear of the engine.

Connect the vacuum hose to the rear engine pad and secure the hose to the gearbox using a tie strap.

Tighten the clamp for the servo line on the subframe.

Installing the exhaust gas recirculation (EGR) cooler

Fig 22: Identifying Exhaust Gas Recirculation Cooler Assembly

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NOTE:

When installing the exhaust gas recirculation (EGR) cooler, ensure that the steel seal and clamp for the cooler flexible hose are located correctly.

Install:

the exhaust gas recirculation (EGR) cooler using the three screws. Tighten to light contact. Then tighten the two M10 screws. Tighten to 50 Nm . Tighten the M8 screw. Tighten to 25 Nm
the hose to the intake manifold
the coolant hoses
the connector for the radiator valve.

Tighten the clamp for the flexible hose.

Installing the vacuum pump

Fig 23: Identifying Vacuum Pump At Cylinder Head

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Check that the vacuum pump seal is undamaged.

Install the vacuum pump together with the connector. Tighten the three screws to light contact. Then tighten to 17 Nm .

Connect both the vacuum hoses to the pump.

Installing the gear selector cable and oil pipe

Fig 24: Gearbox Cables Pipes And Hoses

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Install:

the oil pipe on the gearbox
the gearbox cable and bracket. Tighten to 25 Nm .

Connect the cable to the lever.

Connect the gearbox connectors and the mounting for the air cleaner (ACL) housing bracket. Press the cable harness mounting into place on the control system cover.

CAUTION:

Check that the transmission bleed hose / valve is not trapped. There is a risk of overpressure in the transmission.

Installing service clips

Fig 25: Gear Selector Cable And Clip

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NOTE:

The automatic transmission has a gear selector cable while the manual transmission has two gear selector cables.

Ensure that the gear selector cable is engaged before fitting the blue clip. Press the clip into position as illustrated.

Fig 26: Clip Positioned In Groove

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Check that the clip is positioned in the groove as illustrated.

Installing engine compartment components

Fig 27: Engine Hoses

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Install:

the inner of the two hose couplings for the passenger compartment heater connecting sleeve in the firewall
the charge air pipe for the turbocharger (TC)
the hose between the intake manifold and charge air cooler (CAC)
the clamp for the cable harness on the engine.

Tighten the nut for the rear engine pad. Tighten to 50 Nm .

Fig 28: Engine Compartment Components

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Install:

the air cleaner (ACL) housing assembly with the intake manifold and connections
the ground lead for the mounting on the engine (where applicable)
the upper torque rod between the wheel arches. Tighten the screws. Tighten to 50 Nm
the screw for the torque rod to engine mounting. Tighten to 80 Nm .

Fill with coolant. Carefully check while reaching operating temperature or test driving that the level remains the same and that there is no leakage.

Also see Transmission Replacement, Post-Checking .

Finishing

Carry out checks after working on the gearbox. See Transmission Replacement, Post-Checking .