Removing and Refitting the Automatic Transmission W/ Removing Engine

Removing and refitting the automatic transmission
Tools

Preliminary work

Remove engine-transmission unit.
Remove the starter.

Removing the automatic transmission
Removing converter bolts
1. Turn crankshaft to the extent that one of the U4, U5 or U6 bores in the belt pulley is aligned with the centring bore in the crankcase.

3. Insert assembly aid 9596 into starter opening.
4. Unscrew converter fastening screws with 6mm hexagon socket through the openings -arrows- in the assembly aid 9596.
5. Pull locating pins (short) 9595/1 out of the belt pulley.
6. Turn crankshaft by 120° so that one of the U4, U5 or U6 bores in the belt pulley is aligned with the centring bore in the crankcase.

Note:
^ The crankshaft is fixed in defined position by inserting the fixing pin.
^ If the fixing pin can not be inserted, check the correct positioning of the belt pulley in relation to the crankcase.

7. Insert locating pins (short) 9595/1 through the belt pulley in the crankcase housing bore.
8. Unscrew converter fastening screws with 6mm hexagon socket through the openings -arrows- in the assembly aid 9596.
9. Pull locating pins (short) 9595/1 out of the belt pulley.
10. Turn crankshaft by 120° so that one of the U4, U5 or U6 bores in the belt pulley is aligned with the centring bore in the crankcase.

13. Unscrew support for positive crankcase ventilation line on engine transport eyebolt.

14. Push locating pins (long) 9595/1 through the opening in the transmission housing to prevent the transformer from falling out.

Removing the automatic transmission

1. Pull vacuum line off the switch-over valve.

2. Unscrew vent line on engine transport eyebolt.

3. Unscrew retaining screw between the transmission and the coolant pipe.
4. Place collection pan for coolant under the transmission.

5. Unscrew fastening screw between ATF cooler and coolant line and pull coolant line out of ATF cooler.

6. Unscrew fastening screw between ATF cooler and coolant line and pull coolant line out of ATF cooler.
7. Attach transmission to workshop crane.

8. Unscrew fastening screws -1 to 7- and pull out transmission to the rear, separating it from the engine.

Refitting the automatic transmission

1. Run in transmission and screw in fastening screws -1 to 7-.

2. Loosen transmission from workshop crane.

3. Insert coolant pipe with new O-ring in ATF cooler and screw in fastening screw.

4. Insert coolant pipe with new O-ring in ATF cooler and screw in fastening screw.

5. Screw in retaining screw between the transmission and the coolant pipe.

6. Screw vent line onto the engine transport eyebolt.

7. Push vacuum pipe onto switch-over valve.

Install converter screw connection

1. Pull fixing pins (long) 9595/1 out of the opening in the transmission housing.

2. Screw on support for positive crankcase ventilation line to the engine transport eyebolt.

3. Screw in converter fastening screws with 6mm hexagon socket through the openings in the assembly aid 9596.

4. Pull fixing pins (short) 9595/1 out of the belt pulley.
5. Turn crankshaft by 120° so that one of the U4, U5 or U6 bores in the belt pulley is aligned with the centring bore in the crankcase.

8. Pull fixing pins (short) 9595/1 out of the belt pulley.
9. Turn crankshaft by 120° so that one of the U4, U5 or U6 bores in the belt pulley is aligned with the centring bore in the crankcase.

12. Pull fixing pins (short) 9595/1 out of the belt pulley.

13. Remove assembly aid 9596 from the starter opening.

Subsequent work
Reworking
Install the starter.
Install engine-transmission unit.