Automatic Transmission Assembly: Fitting

When fitting a new transmission, transfer the holder for the torque converter from the new transmission to the old one.

1. Turn the torque converter so that the bolt holes line up with the holes in the drive plate.

   Fit 87 92 574 HOLDER  for holding the torque converter in place while fitting.

   Fig 1: Fitting Special Tool

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2. Make sure the two guide sleeves are on the engine and apply anti-corrosion agent to the sleeves.

   Fit new drive shaft seals, lubricate them before fitting. Use 87 92 657 FITTING DRIFT, DRIVE SHAFT SEALS  .

3. Lift up the transmission with an engine lift and 87 92 442 LIFTING CABLE  .
4. Fit 87 92 608 HOLDER FOR SINGLE-COLUMN LIFT  onto a column jack.
5. Secure the tool to the transmission as for removal.
   IMPORTANT: The jack can tip over. Be careful.
   Fig 2: Fitting Special Tool On Transmission

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6. Fit 83 95 162 PROTECTIVE COLLAR, DRIVE SHAFTS  in the right shaft seal in the transmission. This is done to protect the seal while the transmission is being fitted. Lubricate the seal.
   Fig 3: Fitting Protective Collar In Right Shaft Seal In Transmission

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7. Place the transmission in position.
   IMPORTANT: Slide in the gearbox until approx. 20 mm are remaining and remove the tool 83 95 162  .
8. Push in the transmission until it is against the mating face. Tighten the bolts between the engine and the transmission that are accessible from below.

   Tightening torque 70 Nm (52 lbf ft) 

   Fig 4: Tightening Bolts Between Engine And Transmission

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9. Remove the lifting tool from the transmission and move away the jack. Fit the bolt into the transmission.

   Tightening torque 22 Nm (16 lbf ft) 

10. Undo the strap and position the power steering cooling coil in place. Make sure it is fitted on the correct side of the rubber seal.
    Fig 5: Positioning Power Steering Cooling Coil

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11. Lower the car and fit the mounting for the engine bracket onto the transmission. Lift up the unit and fit the bolts for the engine bracket as marked earlier.

    Tightening torque 93 Nm (69 lbf ft) 

    Fig 6: Fitting Mounting Engine Bracket Onto Transmission

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12. Remove the lifting beam and undo the lifting eyes. Fit the expansion tank in its holder.
13. Fit the remaining upper bolts in the transmission. Use 87 92 723 ACCESS TOOL, BOLT IN JOINT  .

    Tightening torque 70 Nm (52 lbf ft) 

    Fig 7: Fitting Remaining Upper Bolts In Transmission

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14. Fit 83 95 162 PROTECTIVE COLLAR, DRIVE SHAFTS  into the sealing ring. Lubricate the sealing ring.
    Fig 8: Illustration For Steps 14-17

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15. Make sure that the drive shaft is clean and then align it with the tool.
    IMPORTANT: Slide in the gearbox until approx. 20 mm are remaining and remove the tool 83 95 162  .
16. Push in the rest of the shaft until the circlip clicks in.
17. Attach the ABS cable to the clip.
18. Raise the car and remove 87 92 574 HOLDER  keeping the torque converter in place. Press the torque converter against the driver plate. Fit the plug.
19. Apply 74 96 268 Thread locking adhesive to the bolts holding the torque converter to the driver plate. Note. Use the original bolts and washers. Using longer bolts will damage the torque converter.
    Fig 9: Illustration For Steps 19 & 20

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20. Fit the 6 bolts without tightening them.
21. Rotate the engine clockwise with the pulley and tighten the bolts once they are all in place.

    Tightening torque 30 Nm (22 lbf ft) 

22. Fit the starter motor with electrical connections.

    Tightening torque 47 Nm (35 lbf ft) 

    Fig 10: Fiting Starter Motor With Electrical Connections

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23. Fit the charge air pipe bracket.

    Tightening torque 20 Nm (15 lbf ft) 

    Fig 11: Fiting Charge Air Pipe Bracket

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24. Change oil cooler hose seals if the transmission is to be refitted. Use 83 90 270 SLIDING HAMMER  , 87 92 319 ADAPTER, 3/8" - M10  and 87 92 756 OIL PIPE PULLER  .
    IMPORTANT: Ensure that the surfaces in the gearbox gasket opening are not damaged.
    Fig 12: Illustration For Steps 24 & 25

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25. Fit new seals lubricated with Vaseline on the oil cooler hoses. Use 87 92 814 FITTING TOOL, OIL PIPE SEAL  .
26. Lubricate the pipes with Vaseline, none-acidic and attach the oil cooler hoses. The pipes press holes into the seals during fitting.
    Fig 13: Attaching Oil Cooler Hoses

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27. Connect the ground cable to the transmission.

    Tightening torque 10 Nm (7 lbf ft) 

    Fig 14: Illustration For Steps 27 & 28

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28. Fit the bracket for the torque arm on the transmission.

    Tightening torque 93 Nm (69 lbf ft) 

29. Place the frame on the trolley lift with the jig.
30. Lift the frame. Make sure the power steering pipe is positioned correctly. Position the suspension arm ball joints in the steering swivel member. Fit the anti-roll bar to the subframe. The opening of the rubber bushes must be facing front.

    Tightening torque 64 Nm (47 lbf ft) 

31. Lift in place the subframe. Steer the guide pins in the fixture to the holes in the body.
32. Fit the subframe bolts and rear brackets. Lift the subframe against the body so that the bushes do not rotate when the bolts are tightened. Remove the trolley lift.

    Tightening torque, subframe: 75 Nm +135°(55 lbf ft + 135°) 

    Tightening torque, rear bracket bolts: 90 Nm +45° (60 lbf ft + 45°) 

    Fig 15: Illustration For Steps 32-34

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    Fig 16: Illustration For Step 32

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33. Fit the steering gear with bolts, washers and nuts.

    Tightening torque 50 Nm +60°(37 lbf ft + 60°) 

34. Fit the engine torque rod to the subframe.

    Tightening torque 70 +90° Nm (52 lbf ft +90°) 

35. Fit the suspension arms to the steering swivel members.
    IMPORTANT: Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.

    Tightening torque 50 Nm (38 lbf ft) 

    Fig 17: Installing Suspension Arms To Steering Swivel Members

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36. Fit the radiator brackets to the subframe. Make sure the upper radiator core mountings are located correctly in the upper brackets.

    Tightening torque 47 Nm (35 lbf ft) 

37. Remove the straps.
38. Set up 83 96 152 Engine centering tool kit and check that the engine is located correctly in relation to the subframe. Remove the centering tool.
    Fig 18: Fitting Radiator Brackets To Subframe

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39. Fit the power steering pipe to the subframe. Insert all the bolts first and then tighten them.
    Fig 19: Fiting Power Steering Pipe To Subframe

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40. Fit a joint clamp on the front pipe and fit the front exhaust pipe to the catalytic converter. Use a new gasket and new nuts.

    Tightening torque: 25 Nm (18 lbf ft) 

    Fig 20: Illustration For Steps 40 & 41

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41. Adjust the joint clamp so that the pipe ends are in the middle. Tighten the joint clamp nuts.

    Tightening torque 40 Nm (30 lbf ft) 

42. Fit the front wing liner section on both sides of the car.
    Fig 21: Illustration For Steps 42-44

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43. Fit the wheels.
44. Fit the spoiler shield. CV: 
45. Lower the car to the floor.
46. Fit the upper bumper shell mountings.
47. Fasten the ground cable to the left engine bracket.
    Fig 22: Illustration For Steps 47, 48, 49 & 51

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48. Fasten the cable to the cable retainer by pulling back the locking sleeve.
49. Fit the gear cable to the selector lever arm.
50. Carry out CHECKING AND ADJUSTMENT, SELECTOR LEVER CABLE  .
51. Fit the transmission ventilation hose. Lubricate the hose sparingly with Vaseline.
52. Plug in the connectors under the control module, fit the battery tray and plug in the control module connector.
    Fig 23: Fiting Battery Tray And Plug In Control Module Connector

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53. Fit the bonnet switch, cooling pipe, main fuse box and battery.
    Fig 24: Illustration For Steps 53 & 54

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54. Fit and connect the battery cables.
55. Fit the battery cover.
    Fig 25: Fiting Battery Cover

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56. Fit the upper engine cover. Put back the engine dipstick.
    Fig 26: Fiting Upper Engine Cover

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57. Fill 3 liters of transmission fluid through the dipstick hole using 87 92 822 OIL FILLER FUNNEL  with hose. Put back the dipstick. Check the fluid level, see CHECKING THE TRANSMISSION FLUID LEVEL  .
58. Remove the wing covers.
59. Carry out Measures after disconnecting the battery.
60. Test drive the car with varying load and engine speed and read off any diagnostic trouble codes. Also check the position of the steering wheel when driving directly forward on a flat road. Adjust if necessary. Carry out ADAPTATION, RESETTING