Gearbox assembly B284 4WD
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Gearbox assembly B284 4WD
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2.
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Place covers over the wings to keep the paintwork clean and protect it from damage.
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3.
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Remove the upper engine cover.
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5.
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Undo the expansion tank cap to release any pressure.
Warning
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The cooling system is under pressure. Hot coolant and steam can escape.
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- Open the cap slowly to release the pressure.
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- Carelessness can cause eye and burn injuries
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6.
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Lift the expansion tank (A) away from its mounting on the bulkhead wall.
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7.
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Remove the upper heat shield (A) from the catalytic converter.
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8.
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Remove the lower heat shield (B) from the catalytic converter.
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9.
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Remove the turbo delivery hose (A) from the turbo.
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10.
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Remove the gear selector cable (A) from the gear selector arm.
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11.
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Remove the cable from the cable retainer (B) by pulling back the locking sleeve.
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12.
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Undo the cable from the rear mounting (C).
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13.
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Remove the gearbox ventilation hose (D).
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15.
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Remove the battery ground cable and wiring harness clamp (A) from the metal bracket.
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16.
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Remove the screw (B) from the coolant pipe attaching lug.
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17.
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Remove the bolts (C) holding the torque converter to the driver plate. Rotate the engine clockwise with the centre bolt on the belt pulley.
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18.
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Lower the car to the floor.
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19.
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Remove the cable duct (B) from the gearbox.
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20.
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Pull out the lock pin, press down the lock and unplug the control module connector (B). Remove the wiring harness.
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27.
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Lower the car to the floor.
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28.
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Remove the coolant pipe (A) from the thermostat housing and hold the pipe out of the way with
83 95 212 Strap
.
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30.
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Mark the location of the bolts on the left-hand engine bracket with a marker pen for correct refitting and remove the bolts (A) from the bracket.
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31.
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Lower the power train with the lifting beam to facilitate removal of the transmission.
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32.
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Raise the car and fit
87 92 608 Holder for single-column lift
onto a column jack. Adjust and fasten the tool in the gearbox as illustrated. Use the M12 holes for the torque rods. Use bolts that are approx. 20 mm longer than the removed bolts.
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33.
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Remove the lower bolts (A) holding the gearbox to the engine, retain the wiring harness mounting at the front bolt.
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34.
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Pull out the gearbox about 10 mm. Undo the plug and press the torque converter towards the gearbox, fit
87 92 574 Holder
for holding the torque converter in place while removing the gearbox.
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35.
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Pull out and let down the gearbox.
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Important
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The jack can tip over. Be careful.
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36.
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Lift the transmission down from the column jack with an engine lift and
87 92 442 Lifting cable
while undoing the lifting tool from the transmission.
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When fitting a new gearbox, transfer the holder for the torque converter and the plugs form the new gearbox to the old one and the gear shift cable lever to the new gearbox.
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1.
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Turn the torque converter so the holes are aligned with the holes on the driver plate and turn the engine so the oval hole in the driver plate is opposite the starter motor opening. Fit
87 92 574 Holder
(A) to secure the torque converter in place while fitting. Lubricate the torque converter locating pin with grease.
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2.
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Make sure the two guide sleeves are on the engine and apply grease to the sleeves.
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3.
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Fit a new drive shaft seal, (does not apply to new gearboxes), lubricate before fitting. Use
87 92 657 Fitting drift, drive shaft seals
, left-hand drive shaft seal. The seal to the right-hand drive shaft is located in the transfer case, replace O-ring (A) if necessary.
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5.
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Secure the tool to the transmission as for removal.
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Important
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The jack can tip over. Be careful.
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6.
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Fit the gearbox to the engine. Tighten the lower bolts between the engine and the gearbox. Fit the upper bolt loosely at the same time to the wiring harness metal bracket.
Tightening torque 60 Nm (44 lbf ft)
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7.
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Remove the lifting tool from the gearbox, move away the jack.
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9.
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Make sure that the drive shaft (B) is clean and then align it with the tool (A).
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Important
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Fit the drive shaft in the gearbox until approx.20 mm are remaining and pull out the tool before the sealing surface of the shaft reaches the shaft seal.
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10.
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Push in the rest of the shaft (B) until the circlip clicks in.
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11.
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Lower the car to the floor.
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12.
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Fit the upper bolts (A) between the engine and the gearbox.
Tightening torque 60 Nm (44 lbf ft)
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13.
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Lift up the unit and fit the bolts (A) to the engine bracket according to the marks made earlier.
Tightening torque 53 Nm (39 lbf ft)
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14.
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Remove the lifting beam and the holder.
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15.
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Align the wiring harness in place and fit the cable duct (B) to the gearbox, plug in the control module connector (A).
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16.
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Connect the air exhaust hose (D).
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17.
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Fit the cable on the cable retainer (B) by pulling back the locking sleeve.
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18.
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Fit the gear cable to the gear selector arm (A).
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19.
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Fit the cable to the rear mounting (C).
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20.
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Fit the lower heat shield (B) to the catalytic converter.
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21.
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Fit the upper heat shield (A) to the catalytic converter.
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22.
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Fit the expansion tank (A).
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26.
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Lubricate the pipes with Vaseline, non-acidic and attach the oil cooler hoses (A). The pipes press holes into the seals during fitting.
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27.
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Apply
Thread locking adhesive, Loctite 242
to the bolts holding the torque converter to the driver plate.
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Important
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Use the original screws and associated washers. If screws that are too long are used then the torque converter will be damaged.
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28.
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Press the torque converter against the driver plate. Fit a bolt (C) in the oval hole in the driver plate.
Tightening torque 60 Nm (44 lbf ft)
Fit the plug.
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29.
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Turn the engine clockwise with the belt pulley and tighten the remaining bolts (C) in the driver plate.
Tightening torque 60 Nm (44 lbf ft).
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30.
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Fit the battery ground cable and wiring harness clamp (A) for the metal bracket.
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31.
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Fit the screw (B) for the coolant pipe attaching lug.
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32.
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Fit the coolant pipe with a new O-ring to the thermostat housing. Lubricate with Vaseline. Do not tighten the screw until the screw for the attaching lug has been fitted.
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34.
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Attach the turbo delivery hose (A) to the turbocharger.
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36.
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Fill with gearbox oil, use a hose and funnel. See List of lubricants and sealants.
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37.
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Fit the filler plug.
Tightening torque 45 Nm (33 lbf ft)
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39.
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Fit the upper engine cover.
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44.
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Remove the wing covers.
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46.
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Test drive the car with varying engine loads and rpm and delete eventual trouble codes. Also check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed.
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