Remove/install transmission with torque converter

AR27.10-S-0500C

Remove/install transmission with torque converter

10.11.09

 

Remove/install

1

Remove engine with transmission (26)

AR01.10-S-2401B

2

Drain transmission oil

AR27.00-S-0200A

3

Unscrew bolt (27) from mounting clamp (28) on transmission (26)



*BA27.55-N-1003-01A

4

Unscrew bolts (3) from mounting clamps (4) on oil pan



*BA27.55-N-1002-01A

5

Unscrew bolt (5) of power assisted steering line (6) to oil pan

 Expose transmission oil lines (1, 2)



*BA46.30-N-1007-01A

6

Unscrew bolts (7) of transmission mounting (8)



*BA27.10-N-1015-04A

7

Detach starter (20)

AR15.30-S-7100B

8

Detach connector from slide box (N1.1)

AR27.10-S-0500-01A

9

Disconnect connector from output rpm sensor (B91.1)

10

Detach connector from turbine speed sensor (B92.1)

11

Detach connector from speedometer sensor (G4)

Only for model 638.244

12

Unscrew bolts (29) of Bowden cable bracket (30)



*BA27.10-N-1016-04A

13

Unscrew banjo bolts (33) and detach transmission oil lines (1, 2)

Risk of damage due to dirt acting on transmission. Replace sealing rings (32) on banjo bolts (33).

 Use lint-free rags.



*BA27.55-N-1005-01A



*BA27.55-N-1006-01A

14

Unscrew bolts (9) of bearing (10) of center drive shaft (11)



*BA33.30-N-1003-07B

15

Undo bolts (21) on striking plate (22) and remove striking plate (22)

 Replace bolts (21).



*BA27.10-N-1017-04A

16

Unscrew nuts (23) of torque converter (34) to clutch plate (24)

 Installation: Insert screw bolts of torque converter (34), when mounting to flange, into bores of drive plate (24).



*BA27.10-N-1018-04A

17

Secure torque converter (34) with holding device (35) to prevent it from falling down

Holding device

*638589004000

18

Unscrew bolt (15) of mounting clamp (16) to bracket (17)

 Only applies to code H06 (air conditioning)

19

Disassemble refrigerant line (18) of AC compressor (19)

 Installation: Replace sealing rings and wet with new compressor oil.

 Only applies to code H06 (air conditioning)



*BA83.40-N-1004-01A

20

Unscrew ground cable (31) on transmission (26)



*BA54.10-N-1004-01A

21

Unscrew bolt (12) of secondary air injection pump line (13) to bracket (14)



*BA33.30-N-1004-07B

22

Undo bolts (25)

Observe installation position of bolts (25).

 Leave one bolt (25) installed until the suspension gear is positioned.



*BA27.10-N-1012-04A

23

Install suspension gear and support transmission (26)

Pay attention to correct positioning of suspension gear in lift support points (36).

Use suitable lifting aid.

 Suspension gear

*638589056200

24

Remove remaining bolt (25)

25

Remove transmission (26) with torque converter (34)

26

Disassemble center drive shaft (11) with bearing (10)

 Installation: Replace shaft seal.

27

Disassemble drive shaft and output flange

 Only when replacing the transmission.

 Puller

*638589013300

 Puller

*638589036300

28

Install in the reverse order

Number

Designation

Model Series 638 with Series 104.900 engine

BA27.10-N-1012-04A

Bolt, automatic transmission to crankcase

M10

Nm

40

M12

Nm

80

BA27.10-N-1015-04A

Bolt, transmission mount to transmission

Nm

60

BA27.10-N-1016-04A

Bolt, bowden cable bracket to transmission

Nm

11

BA27.10-N-1017-04A

Bolt, (microencapsulated) closing plate to transmission

Nm

15

BA27.10-N-1018-04A

Nut, torque converter to drive plate

Nm

57

Number

Designation

Model Series
638.244/294
with Series
104.900
engine and code G40

BA27.55-N-1002-01A

Bolt, oil cooling hoses to oil pan

Nm

8

BA27.55-N-1003-01A

Bolt, oil line mounting clamp to oil pan (engine)

Nm

8

BA27.55-N-1005-01A

Banjo bolt, oil feed line to transmission

Nm

25

BA27.55-N-1006-01A

Banjo bolt, oil return line to transmission

Nm

25

Number

Designation

Model Series 638 with Series 104.900 engine

BA33.30-N-1003-07B

Bolt, bearing from center drive shaft to bearing bracket

Nm

27

BA33.30-N-1004-07B

Bolt, bearing mount to engine

Nm

50

Number

Designation

Model
638 with steering 763.000

BA46.30-N-1007-01A

Bolt, power steering oil pressure hoses to oil pan

Nm

7.5

Number

Designation

Model 638

BA54.10-N-1004-01A

Bolt with nut, ground cable to transmission

Nm

51

Number

Designation

Model 638

BA83.40-N-1004-01A

Bolt for pressure lines to air conditioner compressor

Nm

21