Transmission Replacement (FWD, LBS/A20DTH)

/ 9-5 (9650) / 2011 / 4. Transmission / / Adjustment/replacement / Transmission Replacement (FWD, LBS/A20DTH)

Special Tools

•	CH-49290 Centering Fixture Subframe - Engine

•	CH-49647 Base Frame

•	DT-47648 Fixture

•	DT-48783 Special Socket

•	EN-47649 Engine Bridge

•	EN 47650 Retainer Plate

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1.	Remove the engine cover. Refer to Engine Shield Replacement .

2.	Remove the battery tray. Refer to Battery Tray Replacement (Diesel) Battery Tray Replacement (LHU/A20NFT) .

3.	Remove the shift lever cable from the selector on the transmission. Refer to Manual Transmission Shift Lever Cable Replacement .

4.	Remove the clutch actuator cylinder hose. Refer to Clutch Actuator Cylinder Pipe Replacement .

5.	Remove fasteners and brackets for the wiring harness on the transmission.

6.	Remove the connector to the reverse light switch.

7.	Remove the upper transmission fasteners (1) using the special socket DT-48783.

8.	Remove the ground cable and the upper fasteners to the starter motor. Refer to Starter Replacement (2.0L Diesel) Starter Replacement (LAU/A28NER) Starter Replacement (LDE/A16XER, LLU/A16LET, 2H0/A18XER) Starter Replacement (LHU/A20NFT) .

9.	Support the engine with engine bridge EN-47649 and retainer EN-47650.

10.	Remove the subframe. Refer to Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNA) Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNB) .

11.

Remove the catalytic converter. Refer to Catalytic Converter Replacement (LAU/A28NER) Catalytic Converter Replacement (LBY/A20DTR) Catalytic Converter Replacement (LLU/A16LET) Catalytic Converter Replacement (LBS/A20DTH) Catalytic Converter Replacement (LHU/A20NFT) Catalytic Converter Replacement (LHU/A20NFT - AWD) .

12.	Remove the rear transmission mount. Refer to Transmission Rear Mount Bracket Replacement .

13.	Remove the transmission front mount. Refer to Transmission Front Mount Replacement .

14.	Remove the starter. Refer to Starter Replacement (2.0L Diesel) Starter Replacement (LAU/A28NER) Starter Replacement (LDE/A16XER, LLU/A16LET, 2H0/A18XER) Starter Replacement (LHU/A20NFT) .

15.	Drain the transmission fluid. Refer to Transmission Fluid Replacement .

16.	Pull out the left driveshaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side (GNA) Front Wheel Drive Shaft Replacement - Left Side (GNB) .

17.	Pull out the right driveshaft from the intermediate shaft and remove the intermediate shaft. Refer to Intermediate Shaft Replacement .

18.	Lower the vehicle.

19.	Remove the fasteners to the transmission mount left side. Refer to Transmission Mount Bracket Replacement - Left Side .

20.	Lower the engine enough to access the transmission.

21.	Raise the vehicle.

22.	Place the transmission fixture DT-47648 on basic frame CH-49647 and attach to the transmission in the holes where the front and rear brackets are mounted.

23.	Remove lower transmission fasteners (1) and (2).

24.	Remove lower transmission fasteners (1) and (2).

25.	Separate the transmission from the engine.

26.	Remove the transmission from the fixture DT-47648.

Installation Procedure

1.	Position the transmission at the fixture DT-47648.

2.	Lubricate input shaft splines and the two guide sleeves.

3.	Attach the transmission to the engine.

4.	Refer to Fastener Caution . Fit the transmission fasteners.

•

Fastener (1) Tighten 60 Nm (44 lb ft)

•

Fastener (2) Tighten 40 Nm (30 lb ft)

5.	Fit the transmission fasteners.

•

Fastener (1) Tighten 60 Nm (44 lb ft)

•

Fastener (2) Tighten 40 Nm (30 lb ft)

6.	Fit the starter motor. Refer to Starter Replacement (2.0L Diesel) Starter Replacement (LAU/A28NER) Starter Replacement (LDE/A16XER, LLU/A16LET, 2H0/A18XER) Starter Replacement (LHU/A20NFT) .

7.	Remove the transmission fixture DT-47648 and basic frame CH-49647.

8.	Lower the vehicle.

9.	Raise the engine to the correct level with the engine bridge EN-47649.

10.	Install the fasteners to the transmission mount left side. Refer to Transmission Mount Bracket Replacement - Left Side .

11.	Remove engine bridge EN-47649 and retainer EN-47650.

12.	Fit the ground cable and the upper fasteners to the starter motor. Refer to Starter Replacement (2.0L Diesel) Starter Replacement (LAU/A28NER) Starter Replacement (LDE/A16XER, LLU/A16LET, 2H0/A18XER) Starter Replacement (LHU/A20NFT) .

13.	Raise the vehicle.

14.	Fit the rear transmission mount. Refer to Transmission Rear Mount Bracket Replacement .

15.	Fit the transmission front mount. Refer to Transmission Front Mount Replacement .

16.	Fit the intermediate shaft. Refer to Intermediate Shaft Replacement .

17.	Fit the left driveshaft to the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side (GNA) Front Wheel Drive Shaft Replacement - Left Side (GNB) .

18.

Fit the catalytic converter. Refer to Catalytic Converter Replacement (LAU/A28NER) Catalytic Converter Replacement (LBY/A20DTR) Catalytic Converter Replacement (LLU/A16LET) Catalytic Converter Replacement (LBS/A20DTH) Catalytic Converter Replacement (LHU/A20NFT) Catalytic Converter Replacement (LHU/A20NFT - AWD) .

19.	Fit the subframe. Refer to Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNA) Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNB) .

20.	Fit the CH- 49290 centring fixture to check alignment.

21.	Fill up the transmission fluid. Refer to Transmission Fluid Replacement .

22.	Fit the clutch actuator cylinder hose. Refer to Clutch Actuator Cylinder Pipe Replacement .

23.	Fit upper transmission fasteners (1) using the special socket DT-48783. Tighten 60 Nm (44 lb ft)

24.	Fit the shift lever cable from the selector on the transmission. Refer to Manual Transmission Shift Lever Cable Replacement .

25.	Fit the fasteners and brackets for the wiring harness to the transmission.

26.	Fit the connector to the reverse light switch.

27.	Fit the battery tray. Refer to Battery Tray Replacement (Diesel) Battery Tray Replacement (LHU/A20NFT) .

28.	Fit the engine cover. Refer to Engine Shield Replacement .

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