Transmission, Remove and Install - AF 20/22
 Remove, Disconnect Remove battery - to do this, remove small relay box. Remove cable from battery positive terminal. Disconnect wiring harness plug (4, 5) from battery box and separate. Only for X 25 XE and Y 26 SE: Remove intake pipe - see operation "Intake Pipe (Above Cylinders 1-3-5), Remove and Install" in group "J". For AF 20/22: If present, remove reservoir for hydraulic system from battery case. Remove hose for transmission ventilation. Disconnect wiring harness plug for selector lever position switch (2) and transmission wiring harness (1) - to do this, open respective retaining clip (3). Press off selector actuation cable (6) from actuation lever and unclip from counterhold (arrows, bottom left). | 
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Remove, Disconnect Remove reaction member (not Z 22 SE). Remove front panel - see operation "Front Panel, Remove and Install" in group "A". Remove inner wing protective panelling - see operation "Protective Panelling - Inner Wing, Remove and Install" in group "A". Remove front axle body - see operation "Front Axle Body, Remove and Install" in group "E". For AF 20, both sides / for AF 22, only left side (not Z 22 SE): Press axle shaft(s) out of transmission with KM-460-2-B (1) and suspend. With AF 22 right side: using soft metal drift drive axle shaft in direction of arrow from intermediate shaft and tie up. Remove supercharger cover for intermediate shaft (2 bolts, "2"). Remove intermediate shaft from transmission.
 Important! AF 20/22: fluid escapes - close off openings. | 
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Remove, Disconnect Remove fluid cooling lines from transmission or side cover - to do this, lever off retaining clamp (2) from quick connection (1) with small screwdriver. Remove fluid cooler line from connecting socket (3) - afterwards re-insert retaining clamp in quick connection - place collecting basin underneath and seal openings. Lower engine with transmission on engine bridge until 3 upper bolts for transmission on engine can be reached. Remove 3 upper bolts for transmission at engine: unscrew front upper bolts (2 piece, "4") with socket wrench extension through left wheel well. Remove rear bolt (5) with suitable wrench from vehicle underside. | 
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Remove, Disconnect Remove cover for converter bolts, for Z 22 SE (lower illustration) remove starter, see operation "Starter, Remove and Install" in group "J". Remove converter from drive disc (6 / 3 bolts). Continue to turn engine clockwise at crankshaft pulley. | 
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Remove, Disconnect Remove bolts (arrows) for transmission on engine oil pan (centre cut-out in illustration shows procedure for Z 22 SE).
 Install, Connect Align Transmission Holder MKM-886 at transmission and secure.
Important! Observe operating instructions for MKM-886. | 
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Remove, Disconnect Remove 2 front lower bolts (arrows) for transmission on engine (illustration shows procedure for Z 22 SE). Remove rear lower bolts (arrows) for transmission at engine. Detach transmission from engine and carefully lower. | 
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Important! Coat centring seat (1) of the converter in the crankshaft with grease. When replacing transmission, ensure that the 2 guide bushings (2) are seated in the engine flange. Re-cut thread (4) in converter for converter bolts and insert with bolt locking compound (red).
 Inspect Check centring pin (3) of converter for frictional rust, clean if necessary. When replacing transmission: Drain fluid cooler as much as possible. Blow out fluid cooler with low-pressure compressed air. Blow out fluid cooler lines at the connections in both directions with low-pressure compressed air. | 
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Install, Connect Attach Transmission Bracket MKM-886 to hydraulic jack. Fasten MKM-886 to transmission - align transmission in slanted position.
Important! Observe manufacturer's instructions for MKM-886 without fail. Raise transmission on hydraulic jack - if necessary align transmission to slanted position again. Transmission to engine flange.
 Tighten (Torque)
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2 lower front bolts (arrows) for transmission to engine - 60 Nm / 44 lbf. ft. |
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2 lower rear bolts (1 and 2) for transmission to engine - 60 Nm / 44 lbf. ft. |
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 Clean It is essential to recut threaded bores of converter.
Tighten (Torque) 3 upper bolts (1) for transmission to engine - 75 Nm / 55 lbf. ft. Remove MKM-886 - use removed bolts for transmission again: 1 bolt for side cover to transmission - 25 Nm / 18 lbf. ft., 1 bolt for auxiliary housing to main housing - 30 Nm / 22 lbf. ft.
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Converter to drive disc (6 or 3 bolts): |
M8 - 30 Nm / 22 lbf. ft. |
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M10 - 55 Nm / 41 lbf. ft. |
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For Z 22 SE |
M10 - 45 Nm / 33 lbf. ft. + 30 ° |
Insert cover for converter bolts. For Z 22 SE: Install starter, see operation "Starter, Remove and Install" in group "J".
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Remove bolts for transmission on oil pan (arrows, lower cut-out in illustration shows procedure for Z 22 SE): |
M8 20 Nm / 15 lbf. ft. |
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M10 - 40 Nm / 29.5 lbf. ft. |
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Install, Connect Raise engine with transmission on engine bridge. Install fluid cooling lines; to do this slide quick fitting onto connecting socket - retaining clamp of the quick connection engages audibly. For AF 22, right side: Insert intermediate shaft into transmission (not for Z 22 SE).
Tighten (Torque) Bearing cover for intermediate shaft to bracket (1) - 18 Nm / 13 lbf. ft.
Install, Connect Position axle shafts with new retaining rings and drive into transmission or onto intermediate shaft at bead of friction welding seam with soft metal drift. Install front axle body - see operation "Front Axle Body, Remove and Install" in group "E". Install reaction member (not for Z 22 SE). Install front panel - see operation "Front Panel, Remove and Install" in group "A". Install inner wing protective panelling - see operation "Protective Panelling - Inner Wing, Remove and Install" in group "A". | 
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Install, Connect Fasten selector actuation control cable to counterbracket - ensure correct engagement. Press selector actuation control cable onto actuating lever for selector lever position switch (ball seat on ball stud).
Inspect Check selector actuation Bowden cable, adjust if necessary - see operation "Selector Actuation Bowden Cable, Adjust".
Install, Connect Connect wiring harness plugs for transmission wiring harness and selector lever position switch and lock. Install hose for transmission ventilation. Only with AF 22: install intake pipe - see operation "Intake Pipe (above cylinder 1-3-5), Remove and Install" in group "J". With AF 20/22: if present, install reservoir for hydraulic system at battery box. Connect 2 wiring harness plug and install at battery box. Install battery and small relay box.
Inspect Correct transmission fluid level - see operation "Transmission Fluid Level, Check and Correct".
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