Gearbox installation Z19

/ 9-5 (9600) / 2006 / 4. Transmission / Manual gearbox / Adjustment/replacement / Gearbox installation Z19

Warning

Cables, hoses, leads etc. are secured with hard plastic cable ties. After being tightened, the ends are cut off, leaving sharp edges at the fixing points. Be aware of the risk of injury due to these sharp ends of cable ties.

Lubricate the primary shaft splines, see List of lubricants and sealing compounds .

Fit 83 95 162 Protective collar, drive shafts in the right-hand shaft seal in the gearbox to protect the seal when the gearbox is refitted.

Important
Always replace the shaft seals in the gearbox. Lubricate with gearbox oil.

Fit the gearbox with a lifting tool on the jack.

Important
Slide in the gearbox until approx. 20 mm are remaining and remove the tool 83 95 162.

Insert the remainder of the gearbox. Turn the crankshaft if necessary to seat the gearbox correctly.

Tighten all bolts except for the top one between the engine and gearbox.

Tightening torque, M12 70 Nm (52 lbf ft)

Tightening torque, M10, 40 Nm (30 lbf ft)

Position the starter motor and fit the lower bolt.

Tightening torque 24 Nm (18 lbf ft)

Remove the lifting tool from the gearbox and lower the jack.

Refit the gearbox bolts.

Tightening torque 24 Nm (18 lbf ft)

Attach the ground lead to the gearbox.

10.

Fit 83 95 162 Protective collar, drive shafts in the left-hand drive shaft seal. Ensure that the driver is clean and then insert the driver in the tool.

Important
Fit the driver 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.

11.

Press in the rest of the shaft until the circlip clicks in.

12.

Fit the rear engine mounting. Place the engine cushion loosely in place.

Tightening torque 60 Nm + 60° (44 lbf ft + 60°)

13.

Lower the car and fit the left-hand engine mounting.

Tightening torque 40 Nm + 30° (30 lbf ft + 30°)

14.

Twist the clutch pressure pipe to the correct position and connect to the gearbox, and fit circlip. Remove the clamp pliers.

15.

Connect a hose to the air nipple and open until brake fluid emerges. Tighten the nipple and test the clutch. If it does not work, perform procedure Bleed brake system.

16.

Connect the reversing light switch connector.

17.

Raise the power train and fit the engine pad nuts and bolts as previously marked.

Tightening torque, nut, up to and including Vehicle Identification Number 73514907:

84 Nm (62 lbf ft)

Tightening torque, nut, from and including Vehicle Identification Number 73514908:

74 Nm (55 lbf ft)

Tightening torque, screws 60 Nm (45 lbf ft)

18.

Fit the upper bolts holding the gearbox to the engine.

Tightening torque 70 Nm (52 lbf ft)

19.

Fill with transmission fluid to the correct level. Fit the filler plug and level plug. See Filling transmission fluid. Cars without level plug: Fill with 2 l transmission fluid.

20.

Raise the car and move the trolley with subframe into position. Lubricate the radiator core guide pins with vaseline. Lift the subframe carefully and guide the pins in.

Important
Be observant of the rubber gaiters for the inner drivers. These can knock against the centre mountings on the subframe before the subframe comes against the body.
Guide in the ball joints.

21.

Fit the subframe bolts and support plate bolts. The fixture locating pins must fit into the holes in the body. Tighten the bolts holding the subframe. Roll the trolley lift away.

Tightening torque 100 Nm + 45° (74 lbf ft + 45°)

Tightening torque, supporting plates 60 Nm (44 lbf ft).

22.

Fit the steering gear bolts.

Tightening torque 90 Nm (66 lbf ft)

23.

Remove the cable tie for the radiator and fit the power steering cooling pipe and clips on the subframe.

24.

Fit the air filter housing on the subframe.

25.

Fit the AC pipe in its plastic clips on the subframe.

26.

Fit the front exhaust pipe. See Front exhaust pipe .

27.

Fit the bolts that hold the outer ball joints to the steering swivel member on both sides. Use new nuts. Tighten the nuts.

Tightening torque 50 Nm (37 lbf ft)

Warning

Check that the spindle on the ball joint protrudes above the steering swivel member attachment.

28.

Fit the anti-roll bars.

Tightening torque 92 Nm (68 lbf ft)

29.

Fit the bolts which hold the torque rod to the subframe.

Tightening torque 90 Nm + 90° (66 lbf ft + 90°)

30.

Lower the car and remove the lifting beam.

31.

Check that the upper guide pins on the radiator core are correctly positioned. Shake the power train to prevent stresses in the engine pads.

32.

Tighten the bolts of the rear engine pad from the engine bay side. Then tighten the nut.

Tightening torque, nuts 26 Nm (19 lbf ft).

Tightening torque, nuts 47 Nm (35 lbf ft).

33.

Fit the shim and gearbox linkage to the gearbox and tighten. Use 74 96 268 Thread locking adhesive on the bolt.

Tightening torque: 20 Nm (15 lbf ft)

34.

Attach the gear linkage to the engine mounting. Use Thread locking adhesive, Loctite 270 .

Tightening torque 8 Nm (6 lbf ft)

35.

Connect the gear linkage to the selector rod.

36.

Select 4th gear and insert lock pin 87 92 632 Lock pin . Tighten the clamp on the gear linkage.

Tightening torque 22 Nm (16 lbf ft)

37.

Remove the lock pins, check the gear positions and that the ignition key can be removed. Insert the plastic plug in the gearbox. Fit the selector lever gaiter.