Removing Transmission
Special Tools
- Support tool No. 999 5033, or equivalent
- Lifting beam tool No. 999 5006, or equivalent
- Hook tool No. 999 5045, or equivalent
- Fitting Hook tool No. 999 5460, or equivalent
- Counterhold tool No. 999 5461, or equivalent
- Plug tool No. 999 5488, or equivalent
- Prying tool No. 999 5462, or equivalent
- Transmission Fixture tool No. 999 5463, or equivalent
- Lifting Fork tool No. 999 5534, or equivalent
- Counterhold tool No. 999 5540, or equivalent
- Universal tool No. 999 5972, or equivalent
- Jack tool No. 998 5972-0, or equivalent
- Refer to special tool section for additional tool information. Tools and Equipment
NOTE: Illustrations only show Right Hand Drive (RHD) and turbo models where these differ.
Procedure
1. Set steering wheel position
- Release steering wheel adjustment lever.
- Push steering wheel in as far as it will go and turn it upwards as far as possible.
Lock steering wheel in position.
- Put shift lever in neutral position.
2. Remove:
- Battery.
- ACL and air intake.
- Disconnect timing valve from ACL. (Turbo models only.)
- Battery shelf.
- ACL bracket retaining screws.
- Turbo models only:
Disconnect clip from turbo air pipe and hose from pipe.
Remove air intake between air filter and turbo unit.
3. Remove:
- Selector cables from bracket and levers.
- Selector link plate by tapping out pin.
- Backup (reverse) light switch connector.
4. Turbo models only:
Remove control pulley cover.
Disconnect:
- Inlet pipe to TB.
Bend pipe sideways with a tie band to hold it clear of TB.
- Upper oil coolant hose to engine oil cooler.
5. Remove:
- Disconnect clutch slave cylinder from transmission.
- Remove circlip.
Note: Leave bellows (gaiter) in place on cylinder.
- Remove:
GND lead from transmission.
Cable tie(s) from engine cable harness.
6. Slacken the nut on the rear engine mounting/splashguard a few turns.
- Remove:
The five bolts holding the starter motor/gearbox.
- Lift the coolant expansion tank clear of the bracket and let it hang free.
- Remove bolt securing cable conduit to subframe near rear of A/C compressor.
- Cars with EGR only:
Disconnect hoses from control valve (A).
7. Remove the bolt holding the steady bar/torque arm to engine.
- Disconnect ground lead from firewall.
- Install lifting fork tool No. 999 5534, or equivalent, between torque arm and engine.
8. Install:
- Support tool No. 999 5033, or equivalent, on guard edges
- Lifting beam tool No. 999 5006, or equivalent, on support
Position beam directly over lugs on lifting fork
- Lifting hook tool No. 999 5460, or equivalent.
Raise hook approx. 5 mm to take some weight off the engine mountings
- Note down the distance between the lifting beam and the spark plug cap
9. Remove:
- Front Wheels
- ABS sensor from wheel spindle (lefthand side)
NOTE: Do not undo connector
Disconnect:
- Brake pipe and ABS cable brackets (both sides)
Unhook brackets and let them hang free
10. Remove:
- Front plastic nuts from L/H fender liner, and any TORX bolts
- L/H hub center nut.
Remove hub center nut locking devices.
Install Counterhold tool 999 5461 (4 wheel bolts) or 999 5540 (5 wheel bolts), or equivalents and remove nut.
Undo driveshaft end from hub.
- Tap driveshaft end approx. 10-15 mm into hub
use plastic or copper mallet
11. Remove:
- Both splashguard bolts
Push guard forward so locating pins on back come loose.
Disconnect guard at front and remove.
- Splashguard under engine (earlier models)
- Nuts to link arms/ball joints (both sides).
Unhook link arms from ball joints.
Take care not to damage ball joint boots
Disconnect and unhook link arms from anti-roll bar (both sides).
12. Remove:
- Cable pipe mounting bolt from subframe and unhook pipe from frame
Disconnect cannister holder and hoses from subframe
- Snip through cable tie to hoses and hang canister from body.
Disconnect the exhaust gas tie behind the Three Way Catalytic Converter (TWC)
13. Remove:
- Oil pipe bracket bolts.
- The two bolts holding the steady bar bracket to the transmission
Drain oil from transmission
NOTE:
- Only if replacing transmission or changing oil.
- Tighten plug to: 35 Nm
14. RHD models only:
Remove impact absorber over steering gear (2 bolts).
15. Disconnect RH Driveshaft
- Remove bearing cap.
- Withdraw driveshaft innards and twist MacPherson strut out of the way
NOTE: Take care not to damage transmission seals.
- Install plug tool No. 999 5488, or equivalent.
- Let driveshaft rest on subframe and oil pipe.
16. Remove bolts from front engine mounting subframe.
- Slacken bolts holding steering gear to engine mounting about one turn.
Remove nuts holding steering gear to subframe (5).
Right-hand drive cars only:
- Remove nut (A) to impact absorber/subframe.
17. Disconnect subframe from car.
- Position jack tool No. 998 5972-0, or equivalent, as support under left-hand side of subframe and tighten up gently.
- Remove fixing bolts holding subframe brackets on both sides.
- Unscrew the two bolts holding the subframe to the body on the right-hand side by about 15 mm.
- Remove bolts on left-hand side.
18. Right-hand drive models only:
- Lower subframe approx. 100 mm.
- Check that the five steering gear bolts and bumper bolts come away from frame.
- Remove anti-roll bar bearing cap bolts (left-hand side).
Undo bolts on right-hand side until they are only held by a few turns.
- Lash anti-roll bar to steering gear as shown in picture.
19. Lower subframe
NOTE:
- Check that steering gear bolts come away from subframe.
- Check that MacPherson strut comes away from RH driveshaft bellows (gaiter).
Remove Jack
- Let frame hang free from bolts on right-hand side.
20. Hang steering gear on left-hand side using hook 999 5045 in hole in frame member flange
(You may also use a bungee cord)
- Remove bolts to engine mounting steering gear and nut on top of engine mounting.
Remove engine mounting.
NOTE: Check that steering gear is hanging properly on hook so that lower steering wheel shaft section does not slip out of steering column.
21. Tape driveshaft end to oil pipe
Disconnect:
- H02S cable terminals from cover.
- Speedometer connector and cable.
Remove:
- Rear engine mounting cover.
- Rear mounting from transmission.
22. Remove left-hand driveshaft.
- Twist MacPherson strut and pull out.
Tap driveshaft end with plastic or copper mallet and pull driveshaft end out of hub.
- Remove driveshaft from transmission.
Use prying tool No. 999 5462, or equivalent, between transmission and inside of driveshaft.
NOTE: Treat driveshaft seals and bellows (gaiters) with care.
Install plug tool No. 999 5488, or equivalent, in transmission.
Clean spline assembly (hub-driveshaft) of metal glue.
23. Lower engine and transmission.
- Using fitting hook tool No. 999 5460, or equivalent, lower until distance between lifting bar and spark plug cover is approx. 320 mm = 12,5".
NOTE:
- Do not lower engine too far, as exhaust pipe may push down on steering gear.
- Check that no leads or hoses are pinched or stretched and that the engine dipstick tube comes away from the fan.
24. Install universal tool 999 5972 and transmission fixture 999 5463 on jack.
Attach transmission fixture to gearbox using fixing bolts from steady bar bracket.
- At the same time, position support plate (marked 5463-2) on the fixture.
- Jack up engine.
25. Remove remaining bolts holding transmission to engine (7).
26. Remove transmission.
- Pull gearbox straight out from engine.
NOTE: Check that transmission actually comes straight away from the engine without any breaks in the clutch plate center.
- Lower jack and move transmission away