vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

ABOUT US
Transmission Replacement - LUJ > < Transmission Fluid Cooler Pipe Connector Replacement - Radiator - 1.4L LUJ

Astra J

Transmission Replacement (LDE)

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 battery tray. Refer to Battery Tray Replacement .
2. Remove 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 front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
5. Drain transmission fluid.

           1999448


6. Disconnect electrical connector (1) transmission control module (TCM), then unclip the connector from the transmission.

           1998666


7. Remove oil cooler inlet (1) and outlet (5) pipes from the retainer (2) from the control valve body cover.
8. Remove transmission fluid cooler inlet pipe nut (3) from the transmission.
9. Remove transmission fluid cooler inlet pipe (1) from the transmission. Refer to Transmission Fluid Cooler Inlet Pipe Replacement .
10. DISCARD the sealing washer.
11. Remove transmission fluid cooler outlet pipe nut (4) from the transmission.
12. Remove transmission fluid cooler outlet pipe (5) from the transmission. Refer to Transmission Fluid Cooler Outlet Pipe Replacement .
13. DISCARD the sealing washer.
14. Plug and/or cap the pipes and transmission to prevent contamination.
15. Remove transmission vent hose.
16. Remove wiring harness starter motor from transmission. Remove bolt from retainer on valve body cover. Unclip wiring harness from retainer on valve body cover and range selector cable bracket.

           2028308


17. Remove the 3 upper transmission bolts (2).
18. Install the EN-47649   support fixture . Refer to Engine Support Fixture .
19. Raise the vehicle.

           2371686



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.
20. Assemble the CH-49290   support tool (1) according to the details provided in the SPX installation manual.
21. Support the CH-904   base frame on a jack.
22. Support the CH-49290   support tool on the CH-904   base frame .

           2371685



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.
23. Install the CH-49290   support tool (1) according to the details provided in the SPX installation manual.
24. Remove the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement .
25. Disconnect the left front wheel drive shaft from transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .
26. Disconnect the right front wheel drive shaft from transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side .
27. Remove the transmission rear mount bracket from the transmission. Refer to Transmission Mount Bracket Replacement - Rear .
28. Remove the transmission front mount from the transmission. Refer to Transmission Front Mount Replacement .

           2191571


29. Remove the starter motor. Refer to Starter Replacement .
30. Remove flap from transmission.
31. Mark the relationship of the flex plate to the torque converter for reassembly.
32. Remove and DISCARD the flex plate to torque converter bolts (1).
33. Lower the vehicle.
34. Remove and DISCARD the 3 left transmission mount bolts from the transmission. Refer to Transmission Mount Replacement - Left Side .
35. Lower the engine and the transmission on the left hand side with the EN-47649   support fixture to allow clearance for removal.
36. Raise the vehicle.

           2027509


37. Place DT-47648   transmission holder onto CH-904   base frame and preinstall the supports as shown in the illustration.
38. Preinstall DT-47648-2   converter housing support (4) to position 1 on the base plate.
39. Preinstall DT-47648-4   transmission housing support (2) to position 14 on the base plate.
40. Preinstall DT-47648-5 left   support with rear transmission swivel arm (1) to position A on the base plate.
41. Preinstall DT-47648-5 right   support with front transmission swivel arm (3) to position F on the base plate.

           2027495



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.
42. Attach the DT-47648   transmission holder to the transmission.
43. Align DT-47648   transmission holder under transmission.
44. Attach swivel arms (1, 2) to transmission.

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

           2028308


48. Remove the transmission bolts (1, 3, 4, 5).

Note:  Insure the torque converter remains securely in place on the transmission input shaft while separating and removing the transmission.
49. Separate the transmission from the engine.
50. 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 3 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 .

           2028308


3. Install the transmission bolts (1, 3) and tighten to 75 N·m (55 lb ft) .
4. Install the transmission bolts (4, 5) and tighten to 45 N·m (33 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 left transmission mount bolts but do not tighten yet.
9. Raise the vehicle.

           2191571



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 old bolts.
10. Install the NEW flex plate to torque converter bolts (1) and tighten to 60 N·m (44 lb ft) .
11. Install flap to transmission.
12. Install the starter motor. Refer to Starter Replacement .
13. Install the transmission rear mount bracket to the transmission. Refer to Transmission Mount Bracket Replacement - Rear .
14. Install the transmission front mount to the transmission. Refer to Transmission Front Mount Replacement .
15. Install the right front wheel drive shaft to the transmission. 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 .

           2028308


18. Remove the EN-47649   support fixture . Refer to Engine Support Fixture .
19. Install the upper transmission bolts (2) and tighten to 75 N·m (55 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 - 75 degrees , using the EN-45059   meter .
22. Raise the vehicle.

           2371685


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 .

           2371686



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.
26. Install the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
27. Lower the vehicle.

           1998666


28. Install the transmission fluid cooler outlet pipe (5) to the transmission. Use NEW sealing washer. Refer to Transmission Fluid Cooler Outlet Pipe Replacement .
29. Install the transmission fluid cooler outlet pipe nut (4) and tighten to 22 N·m (16 lb ft) .
30. Install the transmission fluid cooler inlet pipe (1) to the transmission. Use NEW sealing washer. Refer to Transmission Fluid Cooler Inlet Pipe Replacement .
31. Install the transmission fluid cooler inlet pipe nut (3) and tighten to 22 N·m (16 lb ft) .
32. Install the oil cooler inlet (1) and outlet (5) pipes to the retainer (2) on the control valve body cover.

           1999448


33. Connect the electrical connector (1) transmission control module (TCM), then clip in the wiring harness to transmission.
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. Install the wiring harness starter motor to transmission. Install bolt to retainer on valve body cover. Clip in wiring harness to retainer on valve body cover and range selector cable bracket.
37. Install the transmission vent hose.
38. Fill the transmission with correct fluid.
39. Fill the transmission to a proper level with the correct fluid. Refer to Transmission Fluid Level and Condition Check and Fluid Capacity Specifications .
40. Install the battery tray. Refer to Battery Tray Replacement .
41. After repairs, refer to Control Module References for programming and set up information.
42. Perform adaptive values learn. Refer to Transmission Adaptive Values Learn .

Transmission Replacement - LUJ > < Transmission Fluid Cooler Pipe Connector Replacement - Radiator - 1.4L LUJ