Contents: Removal ⇊ Installation ⇊
Removal
1. Jack up the car and remove the front wheels and mudguards.
2. Unscrew the drain plug (A) and drain the working fluid.
3. Remove the gasket (B) from the drain plug.
4. Disconnect the cable from the negative terminal of the battery, and then from the positive terminal.
5. Remove the battery and battery tray.
6. Remove the inlet manifold.
7. Disconnect the wires (A) from the starter and detach the wire retainer (B).
8. Loosen the bolt and disconnect the ground wire (A). Disconnect the torque converter lock-up solenoid valve connector (B). Disconnect the wire retainer (D) from the bracket (C).
9. Disconnect the transmission output shaft speed sensor connector (A) and the sensor wire retainer (B).
10. Disconnect the vehicle speed sensor connector (A) and the wire retainer (B).
11. Remove the start inhibit switch connector (C) from the bracket (D) and disconnect the connector. Disconnect the wire retainer (E) from the bracket.
12. Disconnect the cooler hoses (A) from the tubes (B).
13. Disconnect the connectors (A) of the pressure control solenoid valves "A" and "B", the connector (B) of the gear shift solenoid valves "A" and "B", the connector (C) of the transmission input shaft speed sensor. Disconnect the retainer (D) from the bracket.
14. Disconnect the oxygen sensor connector (A) and remove the connector from the bracket (B). Disconnect the wire from the retainer (C).
15. Remove the bolt (D) and nut (E) of the front support.
16. Fasten the earring (B) to the stud (A) and hang up the engine.
17. Using a hex key (A) (5 mm) to hold the pin (C) of the ball joint (B) of the stabilizer link, loosen the nut. Disconnect the front suspension stabilizer link from the front suspension lower arm (D).
18. Remove the cotter pin (E) and nut (F). Disconnect the lower arm (D) of the front suspension from the steering knuckle (G).
19. Remove the protective cover (A) of the gearbox control cable and unscrew the cable bracket mounting bolts (B).
20. Remove the cotter pin (C) and take out the pin (D). Disconnect the cable (F) from the gearshift lever (E) and remove the cable.
21. Loosen the nut, remove the bracket (A) and place the transmission control cable (B) to the side.
22. Apply marks (C) to the flanges of the transfer case (B) and the propeller shaft (A).
23. Disconnect the propeller shaft from the transfer case.
24. Loosen the bolts and remove the protective bracket (A) of the propeller shaft.
25. Unscrew the rear support bolt.
26. Apply marks (A) as shown in the figure on the center of the bolt (10 mm).
26. Install the wooden block as shown in the figure.
27. Remove the bolts (A), then remove the mounting bolts (B) and remove the subframe (C).
28. Remove pipe "A" (intake pipe) exhaust systems and catalytic converter.
29. To hold the propeller shaft, install the propeller shaft guard.
30. Loosen the bolts and remove the brackets (A) and casing (B).
31. Rotate the crankshaft pulley and unscrew the 8 bolts (C).
32. Remove the drive shaft (A) from the gearbox.
33. Wrap the drive shaft with a rag (B) as shown in the figure.
34. Loosen the bolts and remove the intermediate drive shaft.
35. Jack up the gearbox.
36. Loosen the gearbox mounting bolts shown in the figure.
37. Loosen the bolt and nuts and remove the gearbox support bracket (A).
38. Loosen the gearbox mounting bolt shown in the figure.
39. Make sure all wires, tubes and cables are disconnected from the gearbox.
40. Disconnect the gearbox from the engine so that the pins are removed from the mounting holes. Then remove the gearbox.
41. Remove the torque converter (B) and starter (C) from the gearbox (A).
42. Loosen the bolts and remove the front support.
43. Loosen the bolts and remove the rear support bracket.
44. Loosen the bolts and remove the torque converter drive plate (A).
Installation
1. Install the rear support bracket and tighten the bolts.
Tightening torque - 44 Nm
2. Install the starter (B) onto the gearbox (A).
Tightening torque - 44 Nm
3. Install a new O-ring (D) and torque converter (C) onto the transmission input shaft (E).
4. Install the pins (F).
5. Jack up the gearbox and connect it to the engine.
6. Tighten the gearbox mounting bolt shown in the figure.
7. Tighten the gearbox mounting bolts shown in the figure.
Tightening torque - 64 Nm
8. Install the support bracket (A) and temporarily tighten the bolt (B). Tighten the nuts (C) and then tighten the bolt (B).
Tightening torque - 54 Nm
9. Install a new snap ring (B) onto the intermediate drive shaft (A) and install the drive shaft.
10. Install a new snap ring (B) onto the drive shaft. Install the right drive shaft (A) into the gearbox. Connect the left drive shaft to the intermediate drive shaft.
Note: Be careful when installing the drive shaft, the splines of the drive shaft can easily damage the seals.
11. While rotating the crankshaft pulley, tighten the 8 bolts (A).
Tightening torque - 12 Nm
12. Install the casing (B) and brackets (C) and tighten the bolts.
13. Install pipe "A" (intake pipe) exhaust systems and catalytic converter.
14. Install the subframe (A) and jack up the subframe using a wooden block (B).
15. Install the subframe (A) and temporarily tighten the subframe mounting bolts (B).
16. Align the marks (B) as shown in the figure with the center of the bolt (10 mm) and tighten the bolts. Finally tighten the subframe mounting bolts.
17. Tighten the rear support bracket bolt.
Tightening torque - 64 Nm
18. Remove the jack.
19. Align the marks (C) on the flanges of the propeller shaft (B) and the transfer case (A), install the propeller shaft and tighten the bolts.
Tightening torque - 32 Nm
20. Position the transmission control cable between the rear support and the subframe.
21. Connect the transmission control cable (B) to the transmission control lever (A). Install the pin (C) and cotter pin (D).
22. Install the cable bracket (E) and protective cover (F).
23. Install the cable bracket as shown in the figure and tighten the nut.
Tightening torque - 10 Nm
24. Connect the lower arm (B) of the front suspension to the steering knuckle (A), tighten the nut (C) and install the cotter pin (D).
25. Connect the front stabilizer bar link (E) to the front suspension lower arm (B). Using the Allen key (F) (5 mm) to hold the stabilizer bar ball joint pin (G), tighten the nut.
26. Install the front support (A) and temporarily tighten the support bolt. Tighten the front support mounting bolts, and then finally tighten the support bolt.
27. Connect the oxygen sensor connector (B) and install the connector on the bracket (C). Place the sensor wire in the retainer (D).
28. Install the dirt protection.
29. Lower the engine and remove the engine suspension cleat.
30. Connect the connector (A) of the shift solenoid valves "A" and "B", the connector (B) of the transmission input speed sensor, the connectors (C) of the pressure control solenoid valves "A" and "B". Install the clamp (D) of the wire harness as shown in the figure.
31. Connect the automatic transmission fluid cooler hoses (A) to the tubes (B).
32. Connect the connector (A) of the starter inhibit switch and install the connector to the bracket. Install the harness retainer as shown in the figure.
33. Connect the vehicle speed sensor connector (D) and the retainer (E).
34. Connect the transmission output shaft speed sensor connector (A) and install the harness clamp (B) as shown in the figure.
35. Connect the torque converter lock-up solenoid valve connector (A) and install the harness retainer (B) to the bracket (C).
36. Connect the ground wire (D).
37. Connect the wires (A) to the starter and secure the wire harness clamp (B).
38. Install the inlet manifold.
39. Install the battery and battery tray.
40. Connect the wires to the battery.
41. Fill the gearbox with working fluid (see chapter "Maintenance and general check and adjustment procedures").
42. Pull the parking brake lever and start the engine. Move the selector lever to each position and make sure that the indication on the selector position indicator corresponds to the selector position. If necessary, adjust the gearbox control cable (see section "Gearbox control cable").
43. Install the mudguards and front wheels.
44. Warm up the gearbox and check the level of the working fluid (see chapter "Maintenance and general check and adjustment procedures").
45. Carry out a check of the mechanical systems (see section "Checking mechanical systems of the gearbox").