A5S 360R/390R AWD Transmission

Remove Automatic Transmission (A5S 360R/390R, 4WD)

Note: After completion of work, check transmission fluid level.

Caution:
Use only the approved transmission fluid in this automatic transmission.
Failure to comply with this requirement will result in serious damage to the automatic transmission!

Disconnect battery, grounding strap to body.





Remove intake hood (1).





Release fan cowl (1) and pull a little upwards.





Remove microfilter housing (1) and heater bulkhead behind it.





Fit special tool 00 0 200 to special tool 00 0 201 / 202 / 204 / 208 and attach.

Suspend special tool 00 0 200 from front engine suspension lug.

Note: Contact faces (1) of special tool 00 0 208 must rest on screw connection of both side walls.





Tighten the screws (1 and 2).





Release nut at top on right engine mount.

Release nut at bottom on left engine mount.





Remove engine underguard (1) at front, middle and rear.

Remove complete exhaust system.





Remove heat shield (1).





Grip clamp bushing (2). Loosen nut (1).

Installation:
Adjust selector lever.





Lift out retaining plate (1) with a screwdriver.

Remove cable (2).





Unfasten screws.

Installation:
Replace self-locking nuts.






Caution: Do not let propeller shaft fall into joints.

Joints and rubber sleeve can be damaged on constant-velocity joint.





Grip propeller shaft.

Unscrew nuts.


Bend propeller shaft downwards at center bearing (1).

Detach propeller shaft from transmission output flange and tie back to side on vehicle underbody.





Installation:
Pull off cover tape from butylene tape on both sides.
Stick butylene tape (1) to outside of center bearing (2).


Caution: Remove butylene tape already attached to center bearing. Clean adhesive area on center bearing and on body. Then coat adhesive area on body with mineral oil. This coating with oil is necessary to facilitate insertion of the sticky butylene tape in the propeller shaft tunnel. This prevents the butylene tape from being deformed.





Installation:
Press center bearing (2) into transmission tunnel.

Remove front propeller shaft.

Remove heat shield on right.

Remove bracket for engine underguard on right.





Support transmission with special tools 00 2 030 / 24 5 301 /245305.





Release screws and remove cross-member (1).






Unlock and remove cable connector (1).
Unclip cable on transmission housing.
Remove transfer case.
Lower transmission.





Unscrew bolt (1).
Withdraw hydraulic lines (2) to oil cooler from transmission housing.

Installation:
Replace sealing rings.

Unfasten steering spindle from steering gear.

This operation is described in the section "Remove power steering".





Raise engine with special tool 00 0 200.





Remove left engine mount.

Install special tool 23 0 230 in place of engine mount.

Note: Engine and transmission are secured at an angle so as to ensure access to top right transmission screw connection.





Unscrew mounting screw.

Press vacuum tank (1) for exhaust flap control to one side.





Lift off cover.





Unfasten retaining screws on torque converter (3 screws) with special tool 24 1 110.


Installation:
Use only original screws.





Preassemble special tool 24 4 131 in conjunction with special tool 24 4 137.





Protect torque converter from slipping out.

To do so, insert special tool 24 4 131/ 24 4 137 in opening in transmission housing.

Clamp torque converter.





Unfasten screws.

Pull off transmission from engine towards rear and lower it.





Installation:
Pay attention to adapter sleeves (1 and 2).

Withdraw damaged adapter sleeves from transmission housing. Insert new adapter sleeves into engine block.

Caution: When joining up engine and transmission, ensure ease of movement of torque converter.





Installation:
The sheet metal flywheel is equipped with three recesses for the torque converter retaining lugs.
When joining together engine and transmission, the three retaining lugs on the torque converter must be aligned with the three recesses in the sheet metal flywheel.
Failure to comply with this requirement leads to secondary damage on the automatic transmission.
The torque converter or engine is not able to spin and would cause damage.





Installation:
Bore on driver must point to center of aperture in cover plate.





Installation:
Twist torque converter on transmission until bores on lugs point to center of bore on flywheel.

Screw special tool 24 2 300 into lug.





Installation:
Raise automatic transmission until bore on driver is reached.
Carefully insert transmission into bore on driver with special tool 24 2 300.
Attach transmission case to engine flange.
Remove special tool 24 2 300 from lug towards front.