Removing and Installing Transmission
Removing and installing transmission
Preliminary work for transmission
1. Disconnect battery.
2. Remove center console cover.
3. Remove shift lever knob.
4. Remove engine guard.
5. Remove rear cardan shaft.
6. Remove front cardan shaft.
7. Remove the starter.
8. Remove clutch slave cylinder.
Removing transmission
Information
^ The cables do not have to be separated from the transmission in order to remove the transmission.
Overview of transmission
1. Remove insulating mat.
Insulating mat for center console
2. Unscrew fastening screws for securing bottom section of gearshift bracket to body.
Threaded joint on bottom section of gearshift bracket
3. Unscrew coolant pipe fastening screws on converter bell housing.
Support for coolant pipes
Information
^ When removing the transfer box, support manual transmission with a wooden block on the suspension subframe.
4. Remove transfer box.
5. Support manual transmission with special tool plate and transmission jack.
Plate
6. Unscrew fastening screws for securing transmission to engine. This involves unscrewing four screws on the engine side and six on the transmission side.
Transmission to V6 engine threaded joint
7. Push out transmission. Pull off vent line for the transfer box.
Support for transmission vent line
8. Remove circlips on support on the transmission.
Disassembly of circlips
9. Remove shift and selector cables from support using special tool removal tool, universal nr.21. Remove selector support with cables.
Disassembly of shift and selector cables
Installing transmission
Information
^ If available: remove assembly aids from production on bottom section of gearshift bracket -arrow-. These were only needed for the first installation in order to align the gearshift bracket.
Removing the assembly aids
Overview of transmission
1. Secure the shift and selector cables to the ball head joint on the support.
Assembly of shift and selector cables
2. Install circlips -inset- on support on the transmission.
Assembly of circlips
3. Raise manual transmission with special tool plate and transmission jack.
Transmission on transmission jack
4. Run in transmission. Connect vent line for the transfer gear.
Vent line holder
5. Screw in fastening screws for securing transmission to engine. This involves screwing in four screws on the engine side and six on the transmission side. -> Tightening torque: 80 Nm (59 ftlb.) -> Tightening torque: 80 Nm (59 ftlb.) -> Tightening torque: 80 Nm (59 ftlb.) -> Tightening torque: 45 Nm (33 ftlb.) -> Tightening torque: 80 Nm (59 ftlb.) -> Tightening torque: 80 Nm (59 ftlb.)
Fastening screws for securing transmission to engine
6. Support transmission with a wooden block on the suspension subframe.
Supporting transmission
7. Remove special tool plate 9725.
Removing plate
8. Insert gearshift bracket into the opening in the center tunnel from below.
Inserting gearshift bracket
9. Install transfer gear.
10. Screw in coolant pipe fastening screws on converter bell housing.
Holder for coolant pipes
11. Screw in fastening screws for securing bottom section of gearshift bracket to body. -> Tightening torque: 24 Nm (18 ftlb.)
Threaded joint on bottom section of gearshift bracket
12. Insert insulating mat.
Insulating mat for center console
13. Fit center console trim.
Subsequent work for transmission
1. Install clutch slave cylinder.
2. Install the starter.
3. Install front cardan shaft.
4. Install rear cardan shaft.
5. Fit engine guard.
6. Install shift-lever knob.
7. Connect battery.