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Range Selector Lever Cable Bracket Replacement > < Transmission Control Replacement

Astra J

Transmission Replacement (2.0L Diesel LBS and LBX)

Special Tools

•  CH-904   Base Frame
•  CH-49290   Engine Support Tool
•  DT-47648   Transmission Holder
•  EN-45059   Angle Meter
•  EN-47649   Engine Support Fixture

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Remove the battery tray. Refer to Battery Tray Replacement .
2. Remove the transmission range selector lever cable and bracket. Refer to Range Selector Lever Cable Bracket Replacement .
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
4. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement .
5. Drain the transmission fluid.
6. Lower the vehicle.
7. Disconnect the electrical connector transmission control module (TCM).
8. Remove the transmission vent hose.

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9. Remove the wiring harness starter motor from transmission. Remove 4 clips (1).
10. Remove the upper middle wiring harness starter motor bracket. Remove the nut.

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11. Remove the 2 upper transmission bolts (2).
12. Install the EN-47649   engine support fixture . Refer to Engine Support Fixture .
13. Raise the vehicle.

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
14. Assemble the CH-49290   support tool (1) according to the details provided in the SPX installation manual.
15. Support the CH-904   base frame on a jack.
16. Support the CH-49290   support tool on the CH-904   base frame .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
17. Install the CH-49290   support tool (1) according to the details provided in the SPX installation manual.
18. Remove the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement .

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19. Remove the starter motor. Refer to Starter Replacement .
20. Mark the relationship of the flex plate to the torque converter for reassembly.
21. Remove and DISCARD the torque converter to flywheel bolts (1).
22. Disconnect the left front wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .
23. Disconnect the right front wheel drive shaft from the front wheel intermediate drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side .
24. Remove the front wheel intermediate drive shaft from the transmission. Refer to Front Wheel Drive Intermediate Shaft Replacement .
25. Remove the transmission rear mount bracket from the transmission. Refer to Transmission Mount Bracket Replacement - Rear .
26. Remove the transmission front mount from the transmission. Refer to Transmission Front Mount Replacement .

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27. Remove the fluid cooler hose from the transmission. Remove nut (1).
28. Remove the catalytic converter. Refer to Catalytic Converter Replacement .
29. Lower the vehicle.
30. Remove and DISCARD the 3 left transmission mount bolts from the transmission. Refer to Transmission Mount Replacement - Left Side .
31. Lower the engine and the transmission on the left hand side with the EN-47649   engine support fixture to allow clearance for removal.
32. Raise the vehicle.

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33. Place DT-47648   transmission holder on CH-904   base frame and pre-install the supports as shown in the illustration.
34. Pre-install DT-47648-2   converter housing support (4) to position 1 on the base plate.
35. Pre-install DT-47648-4   transmission housing support (2) to position 14 on the base plate.
36. Pre-install DT-47648-5 left   support with rear transmission swivel arm (1) to position A on the base plate.
37. Pre-install DT-47648-5 right   support with front transmission swivel arm (3) to position F on the base plate.

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Note:  Before placing in position slacken all bolt connections of the swivel arms and supports as far as the base plate. Adjust the supports for the converter housing and transmission housing using the spindles until they are as low as possible.
38. Attach the DT-47648   transmission holder to the transmission.
39. Align DT-47648   transmission holder under transmission.
40. Attach swivel arms (1, 2) to transmission.

Note:  Align the swivel arms so that as little leverage as possible is created.
41. Tighten the bolt connections of the swivel arms, starting from the transmission and going as far as the base plate.
42. Position supports for converter housing and transmission housing on transmission by twist up the spindles (3).
43. Tighten bolt connections of the supports.

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44. Remove the transmission bolts (1, 3, 4).

Note:  Insure the torque converter remains securely in place on the transmission input shaft while separating and removing the transmission.
45. Separate the transmission from the engine.
46. Lower the transmission with the transmission jack and DT-47648   transmission holder far enough to remove the transmission.

Installation Procedure

1. If the removed transmission will be reinstalled, re-cut the 6 threads of torque converter.
2. Raise the transmission with the transmission jack and DT-47648   transmission holder and position the transmission to the engine.

Caution: Refer to Fastener Caution .

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3. Install the transmission bolts (1, 4) and tighten to 60 N·m (44 lb ft) .
4. Install the transmission bolt (3) and tighten to 40 N·m (30 lb ft) .
5. Remove the transmission jack with the DT-47648   transmission holder .
6. Lower the vehicle.
7. Raise the engine and the transmission on the left hand side with the EN-47649   engine support fixture .
8. Install the 3 NEW transmission mount bolts but do not tighten yet.
9. Raise the vehicle.

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Note:  Service may offer bolts that are not microencapsulated. If this is the case apply thread lock agent to the bolts.
 If fasteners are microencapsulated, install NEW torque converter to flywheel bolts. DO NOT reuse the old bolts.
10. Install the NEW torque converter to flex plate bolts (1) and tighten to 60 N·m (44 lb ft) .
11. Install the starter motor. Refer to Starter Replacement .
12. Install the transmission rear mount bracket to the transmission. Refer to Transmission Mount Bracket Replacement - Rear .
13. Install the transmission front mount to the transmission. Refer to Transmission Front Mount Replacement .
14. Install the front wheel intermediate drive shaft to the transmission. Refer to Front Wheel Drive Intermediate Shaft Replacement .
15. Connect the right front wheel drive shaft to the front wheel intermediate drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side .
16. Install the left front wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .
17. Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement .

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18. Remove the EN-47649   engine support fixture . Refer to Engine Support Fixture .
19. Install the upper transmission to engine bolts (2) and tighten to 60 N·m (44 lb ft) .
20. Tighten the 3 NEW left transmission mount bolts a first pass to 50 N·m (37 lb ft) .
21. Tighten the 3 NEW left transmission mount bolts a final pass to an additional 60 to 75 degrees , using the EN-45059   meter .
22. Raise the vehicle.

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23. Lower the CH-49290   support tool (1) with the CH-904   base frame and a jack.
24. Remove the CH-49290   support tool from the CH-904   base frame .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
25. Disassemble the CH-49290   support tool (1) according to the details provided in the SPX installation manual.

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26. Install the fluid cooler hose to transmission. Install nut (1) and tighten to 9 N·m (80 lb in) .
27. Install the catalytic converter. Refer to Catalytic Converter Replacement .
28. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement .
29. Lower the vehicle.

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30. Connect the electrical connector transmission control module (TCM).

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31. Install wiring harness starter motor to transmission. Install 4 clips (1).
32. Install upper middle wiring harness starter motor bracket. Install nut.
33. Install transmission vent hose.
34. Install the transmission range selector lever cable and bracket. Refer to Range Selector Lever Cable Bracket Replacement .
35. Adjust the automatic transmission range selector lever cable. Refer to Range Selector Lever Cable Adjustment .
36. Fill the transmission with correct fluid.
37. Check transmission fluid level. Refer to Transmission Fluid Level and Condition Check .
38. Install the battery tray. Refer to Battery Tray Replacement .
39. After repairs, refer to Control Module References for programming and set up information.
40. Carry out adaptation, resetting and program the gear selector position sensor in "N" neutral position, using the scan tool. Refer to Transmission Adaptive Functions .

Range Selector Lever Cable Bracket Replacement > < Transmission Control Replacement