Removing and Installing Transmission
Removing and installing transmissionTools
Preliminary work for transmission
1. Disconnect battery .
2. Remove centre 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.
Preliminary work for transmission
1. Disconnect battery.
2. Remove centre console cover.
3. Remove shift lever knob.
4. Remove engine guard .
5. Remove rear cardan shaft.
6. Remove front cardan shaft.
7. Remove clutch slave cylinder.
Removing transmission
Note: 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 centre 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 bellhousing.
Support for coolant pipes
Note: When removing the transfer box, support manual transmission with a wooden block on the suspension sub frame.
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
Note: Screws which are tightened with a torque angle must be replaced with new ones.
7. Screw in new fastening screws -A- for transmission crossmember.
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
Removing transmission
Note: The cables do not have to be separated from the transmission in order to remove the transmission.
1. Remove insulating mat. Centre console sound absorber
2. Unscrew fastening screws for securing bottom section of gearshift bracket to body. Threaded joint on bottom section of gearshift bracket
3. Remove reference mark sender on the transmission
bellhousing. Reference mark sender
4. Unscrew coolant pipe support threaded joint on the transmission bellhousing. Support for coolant pipes
5. Pull off cable plug for neutral switch.
6. Pull off cable plug for back-up light switch.
7. Remove transfer box.
8. Remove breather pipe. To do so, undo the fastening screws -1- and -2- on the transmission.
9. Support manual transmission with special tool plate and transmission jack.
10. Unscrew fastening screws -arrows- for securing transmission to engine.
11. Screw in fastening screws for securing bottom section of gearshift bracket to body. Tightening torque 18 ft. lbs.
Threaded joint on bottom section of gearshift bracket
12. Insert insulating mat. Insulating mat for centre console
13. Fit centre console trim.
Installing transmission
Note: 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. Fasten 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 box.
Vent line support
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 59 ft. lbs. Tightening torque 59 ft. lbs. Tightening torque 59 ft. lbs. Tightening torque 33 ft. lbs. Tightening torque 59 ft. lbs. Tightening torque 59 ft. lbs.
Fastening screws for securing transmission to engine
6. Support transmission with a wooden block on the suspension sub frame.
Supporting transmission
7. Remove special tool plate 9725.
Removing plate
8. Insert gearshift bracket into the opening in the centre tunnel from below.
Inserting gearshift bracket
9. Install transfer box.
10. Screw in coolant pipe fastening screws on converter bellhousing. Support for coolant pipes
11. Screw in fastening screws for securing bottom section of gearshift bracket to body. Tightening torque 18 ft. lbs.
Threaded joint on bottom section of gearshift bracket
12. Insert insulating mat. Insulating mat for centre console
13. Fit centre console trim.
Installing transmission
Note: If present: Remove assembly aids from production on the bottom section of the selector console -arrow-. These were only needed for the first installation in order to align the shift console. Assembly aid on bottom section of gearshift bracket
1. Fasten the shift and selector cables to the ball head joint on the support.
Assembly of shift and selector cables
2. Install snap rings -enlarged view- on support bracket 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 box.
Vent line support
5. Screw in fastening screws for securing transmission to engine. Tightening torque 59 ft. lbs.
Mount engine to transmission
6. Support transmission with a wooden block on the suspension sub frame.
Supporting transmission
7. Remove special tool plate 9725.
Plate
8. Install breather pipe. To do so, screw in the fastening screws -1,2- on the transmission. Tightening torque 17 ft. lbs. Tightening torque 6.5 ft. lbs.
Clutch bell-housing breather pipe
9. Install transfer box.
10. Attach cable plug for back-up light switch.
11. Push on cable plug for neutral switch.
12. Screw in fastening screws for coolant pipe support to the transmission bellhousing.
Support for coolant pipes
13. Install reference mark sender on the transmission bellhousing.
Reference mark sender
14. Screw in fastening screws for securing bottom section of gearshift bracket to body. Tightening torque 18 ft. lbs.
Threaded joint on bottom section of gearshift bracket
15. Install insulating mat. Insulating mat for centre console
16. Install centre 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.