Contents: Dismantling ⇩ Assembly ⇩
Before disconnecting the battery, make sure that all requirements and conditions contained in the section on disconnecting the battery are met.
GENERAL INFORMATION, Precautions when working with electrical equipment.
Dismantling
1. Place the vehicle on a lift.
2. Disconnect the negative terminal from the battery.
3. Using tools LRT-12-214 and LRT-12-215, loosen the viscous coupling mounting nut and remove it together with the fan from the cooling system pump shaft.
NOTE: This thread is left hand.
4. Remove the air duct.
HEATING AND VENTILATION, REPAIR WORKS, Air intake box.
5. Disconnect the connector from the lock switch connector.
6. Release the fasteners securing the left oxygen sensor cable to the automatic transmission housing.
7. Remove the two upper Torx screws securing the automatic transmission housing.
8. Raise the car on a lift.
9. Remove the rear propeller shaft.
DRIVE SHAFTS, REPAIR WORK, Cardan shaft - rear.
10. Remove the front propeller shaft.
DRIVE SHAFTS, REPAIR WORK, Cardan shaft - front.
11. Unscrew 5 nuts and remove the right heat shield.
12. Drain the working fluid from the automatic transmission housing.
AUTOMATIC TRANSMISSION - ZF 5HP24, ADJUSTMENTS, Automatic transmission fluid - draining and filling.
13. Using the LRT-44-032 tool, support the automatic transmission on a jack. The arrow in the figure points toward the front of the vehicle.
14. Remove the bolt and nut connecting the transmission support assembly to the cross frame.
15. Remove the 6 cross frame mounting screws and remove the cross frame.
16. Remove the silent blocks from the support.
17. Lower the gearbox using a jack.
CAUTION: Do not allow the transmission to hang by the gear selector cable.
18. Remove the connector from the transfer case gear shift drive unit connector.
19. Disconnect the connector from the automatic transmission connector.
20. Disconnect the fasteners securing the oxygen sensor cables to the transfer case.
21. Loosen the nut securing the selector lever to the gearbox selector shaft and remove the selector lever.
22. Remove the two screws from the selector cable mounting bracket to the gearbox and secure the cable to the side.
23. Remove the crankshaft position sensor mounting screw, remove the sensor and place it aside.
24. Remove the right oxygen sensor cable from the automatic transmission housing.
25. Remove the protective shield.
EXTERIOR PARTS, REPAIR WORK, Engine protection - front.
26. Remove the plug from the torque converter housing to gain access to the torque converter mounting screws.
27. By turning the engine shaft, open access to the four screws securing the drive flange to the torque converter and unscrew them.
28. Remove the two starter mounting screws and secure the starter to the side.
29. Remove the screw securing the coolant pipe clamp to the automatic transmission pan.
30. Remove the bolt securing the cooler pipe end to the left side of the automatic transmission housing and discard the sealing gaskets.
31. Remove the cooler line from the right side of the automatic transmission case and discard the O-ring.
32. Remove the 8 Torx screws securing the automatic transmission housing.
33. With the help of an assistant, carefully remove the automatic transmission assembly from the engine. The torque converter should remain with the automatic transmission.
34. Install the torque converter retaining plate and secure it with screws.
Assembly
1. Clean all surfaces to be joined.
2. Remove the torque converter retaining plate.
3. With the help of an assistant, carefully install the automatic transmission assembly onto the engine. Ensure that the centering parts of the torque converter and the automatic transmission housing are aligned.
4. Install the 8 Torx screws securing the automatic transmission to the engine and tighten them to 45 N·m (30 lb ft).
5. Wipe the ends of the coolant pipes and the mating surfaces of the crankcase.
6. Install the cooler line to the left side of the automatic transmission case.
7. Lubricate the new sealing gaskets with working fluid, tighten the pipeline fastening screw and tighten it to a torque of 37 N·m.
8. Install a new sealing ring onto the end of the cooler pipe, connect the pipe to the automatic transmission case and tighten the mounting nut to 37 N·m.
9. Install the coolant pipe clamp, tighten the screw and tighten it to 6 Nm.
10. Install the starter, tighten the mounting screws and tighten them to a torque of 45 N·m.
11. Tighten the torque converter mounting screws to the drive flange to a torque of 45 Nm.
12. Install the plug on the torque converter housing.
13. Replace the protective shield.
EXTERIOR PARTS, REPAIR WORK, Engine protection - front.
14. Secure the oxygen sensor cables to the automatic transmission housing.
15. Clean the engine shaft position sensor and mating surface.
16. Install the engine shaft position sensor in place, tighten the mounting screw and tighten it to a torque of 6 N·m.
17. Install the selector cable mounting plate on the gearbox housing, tighten the screws and tighten them to a torque of 10 Nm.
18. Connect the selector lever to the lock switch, tighten the nut and tighten it to a torque of 10 N·m.
19. Install and secure the clamps securing the oxygen sensor cables to the transfer case.
20. Connect the connector to the automatic transmission connector.
21. Connect the connector to the transfer case gear shift drive unit connector.
22. Raise the gearbox with a jack.
23. Install silent blocks.
24. Connect the cross frame to the support, install the bolt and nut, but do not tighten them completely.
25. Install the cross frame, tighten the mounting screws and tighten them to a torque of 68 N·m.
26. Remove the jack from under the gearbox.
27. Tighten the nut and bolt securing the support to the cross frame to a torque of 100 Nm.
28. Install the heat shield and tighten its mounting nuts.
29. Install the rear propeller shaft.
DRIVE SHAFTS, REPAIR WORK, Cardan shaft - rear.
30. Install the front propeller shaft.
DRIVE SHAFTS, REPAIR WORK, Cardan shaft - front.
31. Lower the vehicle.
32. Install the two upper Torx type screws securing the automatic transmission housing and tighten them to 25 N·m.
33. Install and secure the left oxygen sensor cable retaining clips to the automatic transmission housing.
34. Connect the pads to the lock switch connector.
35. Reinstall the air duct.
HEATING AND VENTILATION, REPAIR WORKS, Air intake box.
36. Install the fan on the pulley and tighten the viscous coupling mounting nut to 40 Nm.
37. Connect the negative terminal to the battery.
38. Fill the automatic transmission with working fluid.
AUTOMATIC TRANSMISSION - ZF 5HP24, ADJUSTMENTS, Automatic transmission fluid - draining and filling.
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