Attention! If a new torque converter or transmission is to be installed, reprogram the ECU using the XR25 tester.
Do not remove the transmission from the vehicle for an intended repair until a professional diagnosis has been made as many checks can only be performed with the transmission installed in the vehicle.
Withdrawal procedure:
- put the car on a lift;
- remove the battery and its pallet;
- remove the protective cover of the power unit;
- remove the front wheels;
- remove the air filter housing and intake duct;
- disconnect the ball end of the selector cable from the multifunction switch;
Pic. 4.38. Disconnecting the ball end (1) selector cable and turning locking rings (2) cable sheaths in different directions (the arrow shows the movable part of the hydraulic distributor)
- remove the outer sheath of the selector cable by turning the two snap rings in opposite directions (pic. 4.38);
Note. Do not move the orange ring during this operation. It may break during removal or installation. If this happens, do not replace the selector cable, as the absence of the ring does not affect the operation of the system.
Pic. 4.39. Modular gearbox connector (arrow)
- disconnect the modular connector (pic. 4.39), freeing his wiring.
Protect the connector from damage by packing it in a waterproof plastic bag;
Pic. 4.40. Harness mounting bracket (1) wires, sensor (2) TDC
- Loosen the wiring harness bracket bolts and remove it (pic. 4.40);
- remove the TDC sensor from the engine;
- install clamps on the hoses on both sides of the oil cooler and disconnect it;
- disconnect the connector from the oxygen concentration sensor in the exhaust gases;
- disconnect both front wheel drive shafts from the box, as described in subsection «Front wheel drive shafts»;
- unscrew the bolts and nuts securing the steering mechanism to the subframe, fix it so that it does not interfere with work; take measures not to damage the pipelines of the power steering;
- disconnect the contact connectors of the input and output speed sensors;
- remove the starter (see section «electrical equipment»);
- remove a reception pipe of system of release of the fulfilled gases;
- disconnect the jet link from the gearbox;
- unscrew the bolts and remove the tires «masses» from the gearbox;
- transfer the gravity of the subframe to the rolling jack;
- connect the hoist to the lifting eyes of the engine and hang it out;
- tie the radiator of the cooling system to the front cross member of the engine compartment, unscrew the subframe mounting bolts and lower it;
- remove the rear gearbox support;
- The torque converter is bolted to the faceplate with three nuts, which can be accessed through the starter hole. Turn the crankshaft clockwise so that the nuts become alternately visible through the hole for the starter, unscrew and remove them;
Attention! Nuts must be replaced after loosening.
- transfer the gravity of the gearbox onto a rolling jack or (which is preferable) on a special stand for the gearbox;
- dismantle the left engine mount;
- lower the gearbox and engine as low as possible, being careful not to damage the A/C compressor;
- transferring the gravity of the gearbox to the rolling jack, loosening, unscrew the bolts and unscrew the nuts securing the gearbox to the engine, remember the location of all nuts, bolts and brackets for correct subsequent installation. Check once again that everything is disconnected and laid aside so that the gearbox can be removed without interference;
- disconnect the automatic transmission from the engine, being careful not to dislodge the torque converter;
Pic. 4.41. Fixing the torque converter with a cord to prevent its displacement
- after removing the box, lower the jack and remove the box from under the car. If the guide bushings have a loose fit, remove them and fold them so they don't get lost. Secure the torque converter by tying it to the gearbox housing through the TDC sensor hole in the clutch housing (pic. 4.41).
Installation order:
- untie the torque converter and align it with the gearbox. Apply a coat of Molykote BR2 moly grease to the torque converter center ring;
- install the guide bushings in their places and clean the threads of the torque converter mounting posts to the faceplate;
- when installing the gearbox, align the torque converter threaded posts with the holes in the faceplate. Apply Loctite Frenbloc anaerobic sealant to the threads of the new nuts, screw them on and tighten to the specified torque;
- connect the selector cable and adjust it as described below;
- perform the remaining operations in the reverse order of removal;
- Finally, top up the box with the correct amount of fluid of the type prescribed, as described above.