Sprinter 2005-2007

Transmission Removal & Installation

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  1. Disconnect the negative battery cable.
  2.  
  3. Apply the parking brake and move the transmission gear selector into Neutral (N) .
  4.  
  5. Drain the transmission fluid.
  6.  
  7. Remove the starter, 2007-08 models only.
  8.  
  9. Remove the transmission oil filler pipe by removing the mounting bolts from the cylinder head and transmission housing. Guide the oil filler pipe up and out of the engine compartment.
  10.  
  11. Remove the exhaust heat shield.
  12.  
  13. Remove the retaining bracket and disconnect the driveshaft from the transmission. Secure the driveshaft out of the way.
  14.  
  15. Remove the transmission cooler lines mounting bracket and disconnect the transmission cooler lines.
  16.  
  17. Disconnect the transmission wiring harness.
  18.  
  19. Disconnect the transmission shift cable.
  20.  
  21. Remove the steering gear from the crossmember and lower.
  22.  
  23. Remove the plastic torque converter access cover.
  24.  
  25. Remove the engine by and hand and remove the torque converter bolts.
  26.  
  27. Support the engine assembly with a suitable jack.
    NOTE
    Use a wooden block between the oil pan and jack to avoid damage to the engine.

  28.  
  29. Remove the vent hose bracket and tie back to one side.
  30.  
  31. Disconnect the ground strap.
  32.  
  33. Remove the bolts on the underside of the transmission. Two bolts on the top of the transmission must remain in the housing.
  34.  
  35. Place a suitable jack under the transmission assembly and raise it slightly. Secure the transmission to the jack with a strap.
  36.  
  37. Remove the rear engine crossmember.
  38.  
  39. Remove the last two transmission mounting bolts.
  40.  
  41. Remove the transmission rearward and then lower. Ensure the torque remains in the bellhousing when the transmission is removed.
  42.  
  43. Remove the torque converter.

    Click image to see an enlarged view

    Fig. Remove the transmission mounting bolts (A) first, remove the engine crossmember (4) nuts (5, 6), then bolts (1) before removing the final bolts (B)-2005-06 transmission removal

  44.  

To install:

  1. If removed, install the torque converter to the transmission. Move the torque covert to the position shown to ensure the bottom bolts are accessible through the inspection cover.

    Click image to see an enlarged view

    Fig. Check the position of the torque converter (1) through the inspection cover (2) when reinstalling-2005-06 Models

  2.  
  3. Ensure the dowel pins are installed in their correct position at the transmission housing flange.
  4.  
  5. Using a suitable jack, raise the transmission into position. Secure transmission on hydraulic jack with a strap or ask an assistant to hold it.
  6.  
  7. Move the transmission into position on the dowel pins and install the two bolts on the top of the transmission. Tighten the bolts to 28 ft. lbs. (38 Nm).
  8.  
  9. Install the vent hose bracket to the transmission and tighten to 28 ft. lbs. (38 Nm).
  10.  
  11. Install the ground strap to the transmission and tighten the bolt to 28 ft. lbs. (38 Nm).
  12.  
  13. Install the remaining transmission mounting bolts and tighten to 28 ft. lbs. (38 Nm).
  14.  
  15. Install rear engine cross member and tighten the nuts to 33 ft. lbs. (45 Nm).
  16.  
  17. Remove the wooden block supporting the engine and remove the jack.
  18.  
  19. Rotate the engine by and install the torque converter bolts. Install the all only hand tight at first, then tighten them in pairs to 37 ft. lbs. (50 Nm).
  20.  
  21. Install the inspection cover.
  22.  
  23. Install the steering gear assembly.
  24.  
  25. Connect the transmission wiring harness.
  26.  
  27. Connect the shift cable.
  28.  
  29. Install the cooler lines and tighten the bracket bolts to 25 ft. lbs. (34 Nm).
  30.  
  31. Install the exhaust heat shield.
  32.  
  33. Install the retaining bracket.
  34.  
  35. Connect the driveshaft to the transmission. For additional information, refer to the following section, "Rear Driveshaft, Removal & Installation.-
  36.  
  37. Install the transmission oil fill pipe. Tighten the mounting bolts to 71 inch lbs. (8 Nm) and install the dipstick.
  38.  
  39. Install the transmission oil drain plug and tighten to 15 ft. lbs. (20 Nm).
  40.  
  41. Install the starter, if removed.
  42.  
  43. Lower the vehicle.
  44.  
  45. Refill the transmission with fluid to the correct level.
  46.  
  47. Test drive the vehicle to ensure proper operation and check for leaks.
  48.  

 
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