Table of contents: Removal 🠇 Refitting 🠇
Removal
1. Chock the rear wheels, apply the handbrake and place the selector lever in the "I" (1st gear) position. Jack up the front of the vehicle and securely support it on axle stands (see "Jacking and vehicle support"). Remove both front roadwheels.
2. Drain the transmission fluid as described in Chapter 1A, then refit the drain plugs, tightening them securely.
3. Remove the battery and battery tray as described in Chapter 5A.
4. Remove the air cleaner and intake duct as described in the relevant Part of Chapter 4.
5. Remove the ECU cover (where applicable) and remove any cable ties from the wiring harness in the vicinity of the ECU wiring connector. Disconnect the wiring connector, remove the retaining strap and withdraw the ECU from its location. Disconnect the remaining connectors from the base of the unit. Lay the ECU on top of the transmission and suitably retain it in place.
6. Where applicable, remove the ECU mounting bracket.
7. Remove the exhaust system front pipe from the manifold as described in the relevant Part of Chapter 4.
8. Remove the starter motor as described in Chapter 5A.
9. Remove the dipstick from the transmission.
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10. Using a hose clamp or similar, clamp both the heat exchanger coolant hoses to minimise coolant loss. Slacken the retaining clips and disconnect both coolant hoses from the heat exchanger - be prepared for some coolant spillage. Wash off any spilt coolant immediately with cold water.
11. Using a large flat-bladed screwdriver, carefully lever the selector inner cable end fitting off the transmission bellcrank balljoint, whilst ensuring that the lever does not move.
12. Unlock the outer cable end fitting at the bracket on the transmission.
13. Extract the circlip securing the selector outer cable to the transmission bracket.
14. Undo the retaining bolts and remove the lower driveplate cover plate from the transmission, to gain access to the torque converter retaining bolts. Slacken and remove the visible bolt then, using a socket and extension bar to rotate the crankshaft pulley, undo the remaining bolts securing the torque converter to the driveplate as they become accessible. There are three bolts in total.
15. To ensure that the torque converter does not fall out as the transmission is removed, secure it in position using a length of metal strip bolted to one of the starter motor bolt holes.
16. Withdraw the rubber retaining pin, disconnect the speedometer cable from the drive and free it from any retaining clips.
17. Disconnect the remaining wiring connectors and vacuum hoses likely to impede transmission removal.
18. Remove the driveshafts as described in Chapter 8.
19. Place a jack with a block of wood beneath the engine, to take the weight of the engine. Alternatively, attach a couple of lifting eyes to the engine and fit a hoist or support bar to take the weight of the engine.
20. Place a jack and block of wood beneath the transmission and raise the jack to take the weight of the transmission.
21. Slacken and remove the centre nut and washer from the left-hand engine/trans-mfesion mounting. Undo the two bolts securing the mounting bracket assembly to the vehicle body, then remove the mounting bracket assembly. Recover the spacer from the stud.
22. Slacken and remove the two bolts securing the rear engine mounting to the transmission. Unscrew the nut and bolt securing the mounting link to the vehicle body and remove the mounting assembly from the vehicle.
23. With the jack positioned beneath the transmission taking the weight, slacken and remove the remaining bolts securing the transmission housing to the engine. Note the correct fitted positions of each bolt as it is removed, to use as a reference on refitting. Make a final check that all necessary components have been disconnected and positioned clear of the transmission so that they will not hinder the removal procedure.
24. With the bolts removed, move the trolley jack and transmission to the left, to free it from its locating dowels.
25. Once the transmission is free, lower the jack and manoeuvre the unit out from under the car. If they are loose, remove the locating dowels from the transmission or engine and keep them in a safe place.
Refitting
26. The transmission is refitted by a reversal of the removal procedure, bearing in mind the following points:
- a) Ensure that the bush fitted to the centre of the crankshaft is in good condition and apply a little Molykote G1 grease to the torque converter centring pin. Do not apply too much, otherwise there is a possibility of the grease contaminating the torque converter.
- b) Ensure that the engine/transmission locating dowels are correctly positioned prior to installation.
- c) Once the transmission and engine are correctly joined, refit the securing bolts, tightening them to the specified torque setting, then remove the metal strip used to retain the torque converter.
- d) Tighten all nuts and bolts to the specified torque (where given).
- e) Renew the driveshaft oil seals using the information given in Chapter 7A and refit the driveshafts to the transmission as described in Chapter 8.
- I) Adjust the selector cable as described in Section 2.
- g) On completion, top-up the cooling system (see "Weekly checks"), then refill the transmission with the specified type and quantity of fluid as described in Chapter 1A.