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Removal and installation of automatic transmission (cars with engines 111.948)
Removal
1. Disconnect the negative cable from the battery.
2. Drain the fluid from the automatic transmission.
3. Drain the coolant.
4. Disconnect the cooling system pipe 3 from the tube 1 (see figure 6.47a, 6.476).
Figure 6.47a. Removing and installing automatic transmission (cars with engines 111.948):
1. Cooling system pipe,
2, 4, 5, 7. Bolt,
3. Cooling system pipe,
6. Lid.
Figure 6.47 b. Removing and installing automatic transmission (cars with engines 111.948):
8, 12. Bolt,
9. Gearbox support,
10. Bridge,
11. Block,
13. Bracket,
15. Thrust bearing.
5. Unscrew bolts 2 and 4, then move tube 1 to the side.
6. Remove the cover 6 of the tray.
7. Remove the bolts 7. Rotate the crankshaft to gain access to all bolts 7. Rotate the crankshaft only 120° in the direction of rotation.
8. Unscrew bolts 5.
9. Remove the subframe with the engine.
10. Remove the intermediate shaft.
11. Disconnect the left axle shaft from the flange.
12. Using lift 14, lift the gearbox with the engine until the gearbox supports 9 are completely unloaded (see figure 6.48).
Figure 6.48. Removing and installing automatic transmission (cars with engines 111.948):
14. Elevator,
17. Hairpin.
13. Unscrew the thrust bearing 15 of the gear selector lever.
14. Unscrew bolt 8.
15. Remove bridge 10 from the subframe.
16. Install block 11 between the support part of the subframe and the pallet.
17. Lower the gearbox and engine so that the engine sits on block 11.
18. Disconnect the cable from bracket 13.
19. Unscrew the gearbox mounting bolts 12 and remove the bracket 13.
20. Remove the gearbox from the engine using a lift.
Installation
21. Installation is carried out in the reverse order of removal. Screw the M8 30mm studs into the torque converter. When installing the gearbox, studs 17 must be aligned with the corresponding hole on the drive disk. Do not overtighten the torque converter to drive plate mounting bolts.
Removal and installation of automatic transmission (cars with engines 601.970)
Removal
1. Disconnect the negative cable from the battery.
2. Drain the fluid from the automatic transmission.
3. Drain the coolant.
4. Disconnect the cooling system pipe 3 from the tube 1 (see figure 6.47).
5. Unscrew bolts 2 and 4, then move tube 1 to the side.
6. Remove the cover 6 of the tray.
7. Remove the bolts 7. Rotate the crankshaft to gain access to all bolts 7. Rotate the crankshaft only 120° in the direction of rotation.
8. Unscrew bolts 5.
9. Remove the subframe with the engine.
10. Remove the intermediate shaft.
11. Disconnect the left axle shaft from the flange.
12. Using lift 14, lift the gearbox with the engine until the gearbox supports 9 are completely unloaded (see figure 6.49).
Figure 6.49. Removing and installing automatic transmission (cars with engines 601.970):
1. Cooling system pipe,
2, 4, 5, 7. Bolt,
3. Cooling system pipe,
6. Lid.
Figure 6.49. Removing and installing automatic transmission (cars with engines 601.970):
8. Block,
9, 12. Bolt,
10. Gearbox support,
11. Bridge,
13. Bracket,
15. Thrust bearing,
16. Cooling system pipe.
13. Unscrew the thrust bearing 15 of the gear selector lever.
14. Unscrew bolt 9.
15. Remove bridge 11 from the subframe.
16. Install block 8 between the support part of the subframe and the pallet.
17. Lower the gearbox and engine so that the engine sits on block 8.
18. Disconnect the cable from bracket 13.
19. Disconnect the cooling system pipe 16 from the oil radiator.
20. Unscrew the gearbox mounting bolts 12 and remove the bracket 13.
21. Remove the gearbox from the engine using a lift (see figure 6.48).
Installation
22. Installation is carried out in the reverse order of removal. Screw the M8 30mm studs into the torque converter. When installing the gearbox, studs 17 must be aligned with the corresponding hole on the drive disk. Do not overtighten the torque converter to drive plate mounting bolts.
Removal and installation of automatic transmission (cars with engines 611.980)
Removal
1. Drain the fluid from the gearbox.
2. Remove engine 1 together with gearbox 5 (see figure 6.50).
Figure 6.50. Removing and installing automatic transmission (cars with engines 611.980):
1. Engine,
2. Starter,
3. Pallet,
4. Bolt,
5. Gearbox.
3. Remove the center drive shaft.
4. Unscrew starter 2 without disconnecting the electrical wiring.
5. Remove the cover on the tray 3.
6. Unscrew bolts 4.
7. Unscrew the gearbox mounting bolts 5.
8. Using lift 6, disconnect gearbox 5 from engine 1 (see figure 6.51).
Figure 6.51. Removing and installing automatic transmission (cars with engines 611.980):
5. Gearbox,
6. Lift,
7. Torque converter,
8. Bolt,
9. Leading disk,
10, 11. Brackets.
9. Unscrew the bracket 10 for fastening the gear shift cable (only if the gearbox is going to be replaced).
10. Unscrew bracket 11 from the gearbox and remove the left flange (only if the gearbox is going to be replaced).
Installation
11. Installation is carried out in the reverse order of removal. Screw the M8 30 mm studs into the torque converter 7. When installing the gearbox 5, the studs 8 must be aligned with the corresponding holes on the drive disk 9. Do not overtighten the bolts securing the torque converter to the drive disk.
Removal and installation of automatic transmission (cars with engines 104.900)
Removal
1. Remove the engine together with the gearbox.
2. Drain the transmission fluid.
3. Unscrew the bolts 3 securing the clamps 4 on the pallet (see figure 6.52a, 6.526).
Figure 6.52a. Removing and installing automatic transmission (cars with engines 104.900):
1, 2. Gearbox oil lines,
3, 5, 7, 9, 12, 15. Bolts,
4, 16. Clamps,
6. Power steering line,
8. Gearbox mount,
10. Bearing,
11. Central shaft,
13. Secondary air supply tube,
14, 17. Bracket,
18. Air conditioning system tube,
19. Air conditioning compressor.
Figure 6.52 b. Removing and installing automatic transmission (cars with engines 104.900):
1, 2. Gearbox oil lines,
3, 5, 7, 9. Bolts,
4. Clamps,
6. Power steering line,
8. Gearbox mounting.
4. Unscrew bolt 27 securing clamp 28 on gearbox 26 (see figure 6.53).
Figure 6.53. Removing and installing automatic transmission (cars with engines 104.900):
1, 2. Gearbox oil lines,
26. Gearbox,
27, 29, 33. Bolts,
28. Clamp,
30. Bowden cable mounting bracket,
31. Ground connection wire,
32. Sealing,
34. Torque converter,
35. Support,
36. Anchor point,
B91.1. Wiring connector of the automatic transmission output shaft speed sensor,
B92.1. Connector of the wiring of the speed sensor of the turbine of the GTR,
N1.1. Valve wiring connector.
5. Unscrew bolt 5 securing tube 6 of the power steering to the pan.
6. Unscrew the bolts 7 securing the gearbox supports 8.
7. Remove starter 20.
8. Disconnect the wiring connector from valve N1.1.
9. Disconnect the wiring connector from the turbine speed sensor B91.1 and the driven shaft sensor B92.1.
10. Disconnect the wiring connector from the G4 vehicle speed sensor.
11. Unscrew bolts 29 of bracket 30 for fastening the Bowden cable.
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12. Unscrew banjo bolts 33 and disconnect oil lines 1 and 2 connected to the gearbox.
13. Unscrew the bolts 9 securing the bearing 10 of the central drive shaft 11.
14. Unscrew bolts 21 securing the rear cover 22, then remove it.
15. Unscrew nuts 23 securing torque converter 34 to drive disk 24.
16. Use support 35 to prevent torque converter 34 from falling.
17. Unscrew bolt 15 securing clamp 16 to bracket 17.
18. Disconnect the air conditioning system pipes 18 from the air conditioning compressor 19.
19. Unscrew the ground connection wire 31 from the gearbox 26.
20. Unscrew bolt 12 securing tube 13 of secondary air supply to bracket 14.
21. Place a lift under the gearbox and lift it up.
22. Unscrew the safety bolt 25.
23. Remove the gearbox together with the torque converter.
24. Remove the drive shaft 11 together with the bearing 10.
Installation
25. Installation is carried out in the reverse order of removal. Replace the drive shaft seal 11.