B204, B234 Engines

NOTE:
- Installation of the transmission (for B 204 and B 234 engines) is described below. The procedure is generally applicable to other engine types.
- In all cases, however, care must be taken to ensure that the distributor cover, connectors and hoses do not become jammed between the rear of the engine and the bulkhead.
- Special tools: 5006, 5033, 5115, 5186, 5972.
- Use universal fixture 5972 to install automatic transmission. Ensure that center of gravity of unit is located at center of fixture.

Fixture 5972:

1. Install transmission.
- Use fixture 5972.
- Check position of torque converter. Refer to step number one "Check position of torque converter". B28, B280 Engines
- Coat torque converter guide and mating hole in crankshaft with a little grease.
- Raise transmission, tilting slightly backward.
- Fit torque converter and carrier plate together. Ensure that torque converter housing is in firm contact with bell housing.
- Tighten transmission in position.
- Attach front exhaust pipe bracket to torque converter housing.
- Remove fixture.

Support Member:

2. Install transmission support member.
- Tighten bolts securing member to side members.
- Secure bump stop to member. Ensure that oxygen sensor (Lambdasond) lead is above member.

Gear Selector Lever:

3. Reconnect gear selector lever.
- Reattach control rod and reaction strut to gear lever arm and reaction arm.
- Refit circlips.

NOTE: Install flat washer in control rod pivot assembly.

Wiring:

4. Reconnect transmission wiring.
- Rejoin wiring connectors.
- Secure wiring to selector lever mounting with cable tie.





5. Reconnect oil pipes to connections on gearbox and tighten nuts.
6. Install fluid dipstick tube and torque to 90 Nm (66 ft.lb).





7. Secure torque converter to carrier plate.
- Insert and finger-tighten all bolts.
- Torque bolts alternately to torque 45 Nm (33 ft.lb)

Reinforcing Bracket:

8. Install reinforcing bracket.
- Tighten bracket in stages.
- Secure bracket to torque converter housing and then to cylinder block.
- Install ventilation grille.
- Install splashguard under engine.





9. Install propeller shaft.
- Use socket 5244.
- Tighten front and rear drive couplings.
- Remount intermediate bearing on support member.

Bolted Joint:

10. Tighten flanged joint in front of catalytic converter.
- Install exhaust pipe front mounting bracket.

Tools:

11. Remove lifting attachments.
- Remove tools 5006, 5033. 5115 and 5186.





12. Tighten two upper bolts in torque converter housing.
- Secure front exhaust pipe to bracket.
13. Connect kickdown cable to throttle pulley and adjust. Refer to "Installation". Service and Repair
14. Fill transmission with fluid.
- Adjust fluid level. Refer to "Checking Fluid". Testing and Inspection

Gear Selector Clearance:

15. Check operation of transmission.
- Reconnect battery ground lead.
- Check clearance of gear selector lever in positions D and N.
- Clearance should be equal to or somewhat less than in positions 1 and 2.
- Check transmission oil level.