Attention! The automatic transmission should be removed only after the cause of the malfunction on the car has been accurately established.
Mark the position of the bolts, as they have different diameters and lengths. When installing the automatic transmission, replace all seals, self-locking nuts, bolts and washers with new ones.
Automatic transmission replacement «A5S 440Z»
The sealing elements of the rear cover of the automatic transmission are shown in Figure 9.5. The removal of the automatic transmission must be carried out in the following order. Prepare fixtures «00.2.030», «24.0.250», «24.1.110», «24.4.131», «24.2.300», «24.4.132», «24.5.301» And «24.5.307». Turn off the power and remove the ignition key. Disconnect wire from «–» AB terminals, which is located behind the right side trim of the trunk.
Remove the front crankcase protection panel, stiffening plate and left and right heat shields (pic. 9.6). Disconnect the loops of the oxygen sensors in the exhaust gas and remove the exhaust system.
Release the wires of the oxygen sensors in the exhaust gas from the clamps, disconnect the nuts on both sides of the rod from the anti-roll bar. Hold the ball head shaft with an open end wrench «flats». Pull the stabilizer forward and remove the rear heat shield.
Mark with paint or a marker the relative position of the engine / automatic transmission and automatic transmission mounting bolts to facilitate subsequent assembly.
Loosen the mounting bolts and disconnect the universal joint disc from the automatic transmission. Only turn the nuts while holding the bolt heads. Take the cardan shaft to the side and fix it on the body with a wire clamp, preventing it from breaking in the hinge.
Release from bracket (on the engine) automatic transmission ventilation duct. Holding the clamping sleeve (1, fig. 9.7), loosen the clamping nut (2).
holding the rope (1, fig. 9.8) against turning by the hex head (2), unscrew the nut (3) and remove the cable from the mounting bracket.
Disconnect the oil line bracket (arrow, fig. 9.9) from the oil pan. Disconnect the oil line bracket from the power steering pump.
Install the oil collecting pan. Unscrew hollow bolt (1, fig. 9.10) oil supply and disconnect the oil line.
Unscrew the coupling (2, fig. 9.11) drain the oil and disconnect the oil line. Move both oil lines to the left.
Attention! fixture «24.5.301» must have two holes with a diameter of 10.1–10.2 mm (pic. 9.12). Only such a device ensures a stable position of the automatic transmission assembly and transfer case (RK) on fixture «24.0.250».
Assemble the fixtures «24.5.301», «00.2.030» And «24.0.250», for which insert the hinge pin into the rear hole of the fixture «24.5.301». Support the automatic transmission and the gearbox with the assembly of fixtures (see fig. 9.2).
Release the wiring harness for the oxygen concentration sensors in the exhaust gas from the holders on the transverse beam of the automatic transmission mounting and remove it from the holders on the automatic transmission housing. Remove bolts (6, see fig. 8.3) and disconnect the transverse beam of the automatic transmission mount from the body.
Attention! Prevent the cardan shaft from falling, otherwise the CV joint and rubber seal may be damaged (arrow, see fig. 10.7).
Loosen the flexible coupling nuts (arrows, see fig. 10.5) and remove the bolts.
Holding the cardan shaft by the intermediate support, unscrew the nuts (arrows, see fig. 10.6) its attachments. Press the propshaft intermediate bearing down and disconnect the propshaft from the automatic transmission output shaft flange. Swing the cardan shaft aside and fasten it to the body with a wire clamp.
Disconnect automatic transmission control loop (pic. 9.13), install a polyethylene cover on the loop, remove the cable from the holders on the automatic transmission case and fix it on the body with adhesive tape or a wire clip.
Undocking loop (1, fig. 9.14) and disconnect it. Close the AL with a polyethylene cover and fix it on the body with adhesive tape or a wire clip. Disconnect loop (2) engine shaft speed sensor, close IIIC with a polyethylene cover and fix it on the body with adhesive tape or a wire clip.
Remove protective cover (plug) with holes in the rear bottom of the crankcase (arrow, fig. 9.15) engine.
Unscrew in order with a key «24.1.110» (pic. 9.16) torque converter mounting bolts to the engine drive plate. To bring the bolt to the hole, turn the engine shaft by the crankshaft pulley bolt clockwise. Make sure that the bolts do not fall inside the block.
Unload the automatic transmission by slightly lifting it with a garage jack, through a wooden gasket under the crankcase, but not by the automatic transmission oil pan. Install, through a wooden spacer, a second garage jack under the engine in the area of \u200b\u200bthe first cylinder or use a lift (see fig. 9.2). This will prevent it from tipping over when the automatic transmission is removed.
Slightly lower the automatic transmission. Turn the front wheels so that when the automatic transmission is lowered, the tie rod is not loaded. Take measures to prevent the torque converter from slipping. To do this, install devices «24.4.131» And «24.4.132» (pic. 9.17) into the automatic transmission crankcase window and tighten it.
Loosen, criss-cross, bolts (arrows, fig. 9.18) securing the automatic transmission to the engine and unscrew them completely. In this case, the automatic transmission relies on a jack or fixture. Together, with an assistant, disconnect the engine and automatic transmission together with the RC, moving them towards you. Remove automatic transmission and RK from under the car. Disconnect the gearbox from the automatic transmission.
Attention! Install only standard automatic transmission engine and torque converter mounting bolts.
The installation of the automatic transmission should be carried out in the reverse order, while it is necessary to check the installation of the centering sleeves (arrows, fig. 9.19). Replace damaged bushings.
Check hole condition (1, fig. 9.20) access to the compensating clutch.
Screw in fixture «24.2.300» into the threaded hole (1, fig. 9.21) on the torque converter. Rotate the torque converter until the tool «24.2.300» will not be aligned with the hole in the compensating sleeve.
Fasten the automatic transmission and engine flanges by screwing in the mounting bolts and wrapping them tightly, by hand.
Screw in the three bolts securing the torque converter to the engine drive plate with a torque of 10 - 15 Nm (1.0 - 1.5 kgf·m). Unscrew fixture «24.2.300» and install the fourth bolt securing the torque converter to the engine flywheel plate. Tighten all torque converter mounting bolts to 45 Nm (4.5 kgf·m).
Check the mating of the automatic transmission and the engine. Return the mounting bolts, along with washers (according to the marking), and preliminarily, according to the principle through one, tighten all the bolts to a torque of 20 N·m (2.0 kgf·m) and remove fixtures «24.4.131» And «24.4.132».
Further tighten the bolts of the automatic transmission to the engine in several stages crosswise, with the final torque indicated below, N·m / kgf·m:
- type bolts «Torx»:
- m8 21/2.1;
- m10 42/4.2;
- hex bolts:
- m8 24/2.4;
- m10 45 / 4.5;
- cross beam bolts - 41 / 4.1;
- oil pipeline bolts - 28 / 2.8 (replace o-rings);
- automatic transmission shock absorber nut - 74 / 7.4;
- filler plug (M18x1.5) – 35/3,5;
- drain plug (M16x1.5) – 30/3,0;
- drain pipe coupling - 28 / 2.8;
- control cable nut - 15 / 1.5;
- nut (M8) control lever - 10 / 1.0.
Adjust the balancer of the control unit. When installing the removed elements, it is forbidden to apply significant efforts so that the parts are not subjected to excessive mechanical stress. Replace automatic transmission seals. Add oil to the automatic transmission and install the cardan shaft.
Attention! When tightening the bolts for fastening the elastic coupling and the rubber-metal shock absorber, rotate only the nuts, and hold the bolts with a wrench so as not to create stress in the coupling body.
Install the cross member on the automatic transmission and the underbody. Tighten the bolts to a torque of 41 Nm (4.1 kgf·m). Tighten the new nut of the rubber-metal shock absorber mounting bolt to 74 Nm (7.4 kgf·m).
Tighten the new nuts of the flexible coupling fastening bolts to a torque of 100.0 Nm (10.0 kgf·m).
Tighten the intermediate support fastening nuts to a torque of 21.0 Nm (2.1 kgf·m).
Install the anti-roll bar on the push rods and secure it with new self-locking nuts, with a tightening torque of 6.0 kgf·m (60 Nm).
Reinstall all removed items. When moving the speed sensor to a new automatic transmission, it must be reconfigured.
Check the oil level in the automatic transmission. Fasten the stiffening plate in two successive steps - with a torque of 56 Nm (5.6 kgf·m) and turn 90°.
If necessary, adjust the gearshift drive and make a test drive with the car with all the options for possible shifts.