Removal
NOTE: Component identifier numbers used in the following illustrations relate to specific steps in the procedures below.
NOTE: Protect the front fenders
1. Remove the battery.
2. Disconnect the battery's negative cable from the transmission.
3. On models with 4 cylinder engine, remove the cable bracket on the dipstick.
4. On all models, remove the dipstick retaining screw.
5. Pull the dipstick and sleeve straight up.
6. Plug the dipstick hole in the transmission.
7. Remove the breather hose from the transmission.
8. Remove the selector lever arm from the transmission.
9. Remove the cable from the bracket on the transmission and bend the cable aside.
10. Unplug the electrical connectors for the transmission.
11. Undo the clamps securing the cables to the transmission.
12. On models with 4 cylinder engine, remove the engine's air cleaner housing.
13. On all models, remove the rubber bushes in the engine's lifting eye.
- 6-cyl: 2 lifting eyes
- 4-cyl: 1 lifting eye
14. Install the lifting beam, tool No. 83 94 850, or equivalent, into position.
CAUTION: Place suitable protective pads or the like under the feet of the lifting beam to avoid damaging the paint work.
15. On models with 6 cylinder engine, install the holder part No. 83 94 835 in the engine's two lifting eyes and connect the lifting beam to the lifting sling and tighten.
16. On all models, unplug the 2 oxygen sensor connectors.
- 6-cyl: 2 oxygen sensors
- 4-cyl: 1 oxygen sensor
17. Raise the car.
18. Remove the lefthand and righthand front wheels.
19. Remove the air deflectors and the cover in the righthand front wheel housing, secured by means of three screws.
20. On models with 4 cylinder engine, remove the bracket for the oxygen sensor cable from the front of the engine.
21. On all models, remove the front section of the exhaust pipe.
22. Undo the nuts securing the end pieces of the steering swivel members and remove the two subframe brackets from the engine.
23. Position a lifting table under the subframe so that the supports on the lifting table are directly below the front engine mounts and transmission.
24. Remove the 6 remaining subframe retaining screws.
25. Lower the lifting table about 2 cm.
26. Detach the suspension arms from the end pieces of the steering swivel members and lower away the subframe.
NOTE: The two rear subframe brackets are also installed with two washers.
27. Remove the transmission fluid cooler's inlet and outlet hoses.
NOTE: Transmission fluid will run out when the inlet and outlet hoses are disconnected.
28. Plug the inlet and outlet holes in the transmission. Also plug the hoses and turn them upwards.
29. Remove the lefthand drive shaft from the automatic transmission by first releasing it from its splines and then withdrawing it carefully straight out of the splines by hand.
- Plug the drive shaft's inlet hole on the automatic transmission with a plastic plug.
NOTE: Transmission fluid will run out when the drive shafts are removed.
30. Secure the drive shaft to the car body so that it will not hang down and be damaged when the car is lowered to the ground.
31. Separate the righthand drive shaft at the intermediate shaft's mounting point on the engine, using separation tool 89 96 654, or equivalent.
NOTE: The drive shaft is connected to the intermediate shaft with splines and is released and secured to the car body in the same way as the lefthand drive shaft.
32. Remove the intermediate shaft's bracket on the engine as follows:
6-cylinder engine:
- Remove the two securing in the securing point and carefully knock the shaft out of the securing point
4-cylinder engine:
- Remove the lower generator bolt.
- Remove the bracket's 3 retaining bolts.
- Swing the generator upwards.
- Pry out the bracket to free the 2 locating dowels.
- Withdraw the intermediate shaft and attendant bracket.
33. Plug its inlet hole with a plastic plug.
34. Remove the splash plate (secured to the transmission by 2 screws) to expose the torque converter's attachment to the drive plate.
35. Remove the six bolts securing the torque converter to the drive plate.
NOTE: The crankshaft will have to be rotated in order to gain access to all the bolts.
36. Install torque converter retainer, to hold the torque converter in position while removing the transmission.
- 6-cylinder engine: specially made grip
- 4-cylinder engine: tool No. 87 92 277, or equivalent
NOTE:
^ Some transmissions are not provided with the hole for installing the tool.
^ It will then be necessary to drill a hole, using a 5 mm drill bit, and cut an 6 mm thread in it.
^ See the illustration.
37. Remove the 2 lower retaining bolts securing the transmission to the bottom of the engine.
- 6-cylinder engine: 4 bolts
- 4-cylinder engine: 2 bolts
38. Remove the front engine mount retaining bolts.
39. Remove the rear-most of the 3 upper retaining bolts.
40. Lower the car to the floor.
41. Lower the engine and transmission by means of the lifting beam until there is a clearance of about 10 cm between the car body and the front transmission mount.
- The clearance can be observed from the lefthand front wheel housing.
42. Fasten lifting wire tool No. 87 92 442, or equivalent, to the transmission's rear securing hole and attach the wire to a hoist.
43. Pull the wire taut by means of the hoist.
44. Remove the 2 remaining upper retaining bolts.
45. Remove the transmission from the engine by carefully inching it loose and lowering it.
46. Detach the wire from the hoist, raise the car and withdraw the automatic transmission.
47. Remove the lifting wire from the automatic transmission.
48. Remove the tool holding the torque converter in position.
NOTE: In connection with transmission replacement, transfer the tool to the old transmission.