Contents: Removal 🠛 Installation 🠛
Attention! If a new torque converter or gearbox is to be installed, reprogram the ECU using the XR25 tester.
Special tool:
- Subframe support - Mot. 1040-01
- Ball joint puller - T.Av. 476
- Brake caliper bolts - 40 Nm
- Lower ball joint nut - 55 Nm
- Shock absorber support bolt - 180 Nm
- Engine tie rod bolt - 65 Nm
- Starter bolt - 45 Nm
- Gearbox support bolt - 40 Nm
- Wheel bolt - 90 Nm
- Steering rod ball joint nut - 40 Nm
- Torque converter clutch nut - 30 Nm
- Heat exchanger support bolt - 50 Nm
- Modular connector support bolt - 20 Nm
Do not remove the transmission from the vehicle for the intended repair until a professional diagnosis has been made, as many checks can only be performed with the transmission installed in the vehicle.
Removal
1. Place the vehicle on a lift.
2. Remove the battery.
3. Remove the front wheels.
4. Remove the air filter duct.
5. Remove the battery tray.
6. Loosen the bolt (2) securing the combination switch cable hinge.
7. Release the switch cable (1) from the central switch retainer.
Figure 4.38. Disconnecting the ball end (2) of the selector cable and turning the locking rings (1) of the cable sheath in different directions (the arrow shows the moving part of the hydraulic distributor)
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.
Figure 4.39. Gearbox modular connector (arrow)
8. Disconnect the modular connector (Figure 4.39), freeing its wiring.
Caution: After disconnecting the connector, put a bag on it to protect it from moisture.
9. Loosen the engine wiring support bracket mounting bolts. Remove the support bracket (1) and TDC sensor (2).
Figure 4.40. Wiring harness (1) mounting bracket, TDC sensor (2)
10. Clamp the heat exchanger hoses and disconnect the hoses.
11. Disconnect the oxygen sensor connector.
12. Remove both drive shafts.
13. Unscrew the steering gear mounting bolts, secure it to the side so that it does not interfere with the removal of the automatic transmission and without damaging the mechanism hoses.
14. Disconnect the vehicle speed sensor connector.
15. Remove:
- starter;
- jet thrust of the engine;
- the exhaust system's receiving pipe.
16. Install the subframe trolley holder Mot.1040-01.
17. Install the engine support and secure the engine to it.
18. Remove the engine subframe.
19. Rotate the crankshaft clockwise to install the three torque converter-to-drive coupling bolts opposite the access hole. Remove the bolts.
20. Remove the automatic transmission support and ground cable.
21. Tilt the power unit as low as possible.
Caution: Be careful not to damage the air conditioning compressor.
22. Unscrew the bolts and upper nuts securing the automatic transmission to the engine.
23. Place a jack under the automatic transmission.
24. Unscrew the bolts and lower nuts securing the automatic transmission to the engine.
25. Carefully disconnect the automatic transmission from the engine. The torque converter should remain on the automatic transmission shaft.
26. Secure the torque converter with twine to the automatic transmission housing.
Figure 4.41. Securing the torque converter with a cord to prevent it from shifting
Installation
- untie the torque converter and align it with the gearbox. Apply a layer of Molykote BR2 molybdenum grease to the torque converter centering ring;
- install the guide bushings in their places and clean the threads of the torque converter mounting posts to the faceplate;
- when installing the transmission, 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 them 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, add the required amount of fluid of the prescribed type to the box as described above.