Transmission, Installing

Procedure

NOTE:

Refer to GENERAL REPAIR INFORMATION .

Refer to TRANSMISSION, CLEAN WORKING CONDITIONS .

When installing, bring all cable ties back to same positions.

-- Check whether bushing -arrow- is inserted at rear of crankshaft. Drive in bushing if necessary.

Fig 1: Identifying Torque Converter Centering Bushing

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-- Check the installed dimension -a- of the torque converter. Refer to TORQUE CONVERTER, INSTALLING .

Fig 2: Measuring Torque Converter

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CAUTION:

If the converter is not properly installed, the drive lugs on the converter and the ATF pump will be severely damaged when the transmission is attached to the engine.

-- Make sure the alignment sleeves -A- for centering the engine/transmission are installed in the engine. Install if necessary.

Fig 3: Bolt Removal Sequence

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CAUTION:

Danger of leaks on the torque converter seal.

The covers -items 3 through 8- OVERVIEW - TORQUE CONVERTER prevent dust and dirt from getting into the torque converter bell housing. Install the covers if necessary.

-- Before putting engine and transmission together, rotate engine torque converter and drive plate so that holes or threaded holes are at the same height as opening on removed starter -arrows-.

Fig 4: Identifying Torque Converter Bolts

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-- Ensure no lines are kinked when sliding engine and transmission together.

-- Always use new bolts to secure the torque converter to the drive plate.

Note the following when installation the transmission.

CAUTION:

Before and during fastening the engine/transmission flange bolts, check that the torque converter can still be turned behind the drive plate. If the torque converter cannot be turned, it must be assumed that it has not been installed properly and that the drive plate of the torque converter or the ATF pump will be destroyed during final tightening of the bolts.

-- Attach the transmission to the engine.

-- Turn the crankshaft 120° in direction of engine rotation and install the torque converter bolts through the opening for the starter and tighten them hand-tight.

NOTE:

The tightening specifications apply only to lightly greased, oiled, phosphated or blackened nuts and bolts.

Additional lubricant such as engine oil or transmission fluid may be used, but do not use graphite lubricant.

Do not use any ungreased parts.

Tightening specification tolerance +/- 15%.

-- Turn the crankshaft 120° in direction of engine rotation and install the torque converter bolts through the opening for the starter and tighten them hand-tight. Refer to TORQUE CONVERTER .

Securing Engine/Transmission

Fig 5: Bolt Removal Sequence

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Item	Bolt	Nm
1, 2	M10 x 70	45
3 ••• 5, 7	M12 x 80	80
6	M12 x 70	80
8 ••• 10	M10 x 70	45
A	Alignment sleeve for centering

Further installation in reverse order, paying attention to the following:

-- Install the starter. Refer to STARTER, REMOVING AND INSTALLING .

-- Install the generator. Refer to GENERATOR, REMOVING AND INSTALLING .

-- Install transfer case. Refer to TRANSFER CASE .

-- Install rear driveshaft. Refer to REAR DRIVESHAFT .

-- Install the ATF lines. Refer to ATF LINES AND ATF COOLER .

-- Check the connectors -1 to 3- at transmission for water entry or contact corrosion, correct if necessary.

Fig 6: Connect Connectors -1 Through 3-

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-- Connect the connectors -1 to 3-.

-- Secure front driveshaft to transfer case. Refer to FRONT DRIVESHAFT .

-- Install the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Install the left rear coolant lines or the left rear coolant pipe to the transmission. Refer to REAR COOLANT PIPE, REMOVING AND INSTALLING .

-- Install the primary catalytic converter. Refer to Exhaust System, Emission Controls .

-- Install the particulate filter. Refer to Exhaust System, Emission Controls .

-- Install the selector lever cable and check the adjustment. Refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING .

-- Align the exhaust system free of tension. Refer to Exhaust System, Emission Controls .

-- Install the wheel housing liner. Refer to Wheel Housing Liners .

-- Install the front wheels.

-- Complete the steps required after connecting the battery. Refer to BATTERY, REMOVING AND INSTALLING .

CAUTION:

Do not use a charging unit as a starting aid. Vehicle control modules could be damaged.

-- Checking and filling. Refer to ATF LEVEL, CHECKING AND FILLING .

-- After Installation an exchanged transmission or after repairing transmission, clean ATF lines and ATF cooler. Refer to ATF LINES AND ATF COOLER, CLEANING .

-- If the transmission was replaced, perform a transmission adjustment. Refer to TRANSMISSION ADAPTATION .

Tightening Specifications

NOTE:

The tightening specifications apply only to lightly greased, oiled, phosphated or blackened nuts and bolts.

Additional lubricant such as engine oil or transmission fluid may be used, but do not use graphite lubricant.

Do not use any ungreased parts.

Tightening specification tolerance +/- 15%.

Component		Nm
Bolts/nuts	M6	9
	M8	20
	M10	40
	M12	65