Shift Cable: Service and Repair
Removing and installing shift and selector cablesTools
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Preliminary work for shift and selector cables
1. Remove engine guard .
2. Remove rear cardan shaft.
3. Remove top section of gearshift bracket.
Removing shift and selector cables
1. Unscrew threaded joint on bottom section of gearshift bracket -arrows-.
Mount of gearshift bracket to body
2. Remove front cardan shaft on the transfer box and tie it up at the side -arrow-.
Attaching the cardan shaft
3. Lower the transmission:
4. Loosen fastening screws securing exhaust system support -centre arrows- to transmission cross member. Catalytic converter
5. Support transfer box with material transmission jack 00000.
6. Unscrew four screws -A- on transmission crossmember.
7. Lower transmission cross member by approximately 55 mm -arrow-.
Distance from transmission cross member to body
8. Remove safety clips -arrows- on support.
9. Release shift and selector cable attachment using disassembly tool, universal 21 on gearshift lever -arrows-.
Removing shift and selector cables
10. Guide the shift and selector cables out of the support.
11. Remove bottom section of gearshift bracket with installed shift and selector cables backwards over the transfer box.
12. Remove safety clips on bottom section of gearshift bracket -1st arrow-, then remove operating cables -2nd arrow-.
Installing shift and selector cables
Overview of shift and selector cable
Note: If present: remove assembly aids from production -arrow-. These were only needed for the first installation in order to align the gearshift bracket.
Assembly aid on bottom section of gearshift bracket
1. Insert shift and selector cables in bottom section of gearshift bracket -1st arrow-, then fit safety clips -2nd arrow-.
Installing safety clips
2. Insert bottom section of gearshift bracket with installed shift and selector cables over the transfer box ->Installing gearshift bracket.
Installing gearshift bracket
3. Guide the shift and selector cables into the support.
4. Pressing the ends of the shift and selector cables onto the ball head joint on the selector lever -arrows-
Assembly of shift and selector cable at transmission
5. Press rubber boots into the support and fit safety clips -arrow-.
Assembly of safety clips on transmission
6. Lift up transfer box with cross member. Position bottom section of gearshift bracket in transmission tunnel -arrow-.
Positioning the bottom section of gearshift bracket
Note: Screws which are tightened with a torque angle must be replaced with new ones.
7. Screw in new fastening screws -A- for transmission cross member.
8. Screw in two fastening screws to secure exhaust system support to transmission cross member -centre arrows-. Tightening torque 17 ft. lbs.
Note: Screws which are tightened with a torque angle must be replaced with new ones.
9. Fix front cardan shaft to transfer box with new screws. Initial tightening 22 ft. lbs. Final tightening 90°.
10. Screw in threaded joint on bottom section of gearshift bracket -arrows-. Tightening torque 18 ft. lbs.
Subsequent work
Touching up for shift and selector cables
1. Install rear cardan shaft.
2. Fit engine guard.
3. Install top section of gearshift bracket.
4. Function test for shift mechanism:
^ Position of gearshift lever?
^ Possible to shift through all gears, including reverse gear?