Removing and Installing Transmission
WM 343519 Removing and installing transmission
Preliminary work
Preliminary work
Warning: Burns and scalding through hot components and fluids
--> Allow vehicle to cool down before beginning work
1. Raise the vehicle at the specified jacking points.
2. Remove wheels.
3. Remove rear silencer.
4. Remove support plate.
5. Unscrew fastening nuts for restraining cables and remove restraining cables from crossmember.
6. Retaining device 9624/3 must be screwed to crossmember. Then turn spindle upwards and support engine.
Special tool
Removing transmission
Dismantling
1. Loosen fastening screws between anti-roll bar and rear axle carrier side panel and fold anti-roll bar forward.
Anti-roll bar
Information: Protect drive shafts against mechanical damage (e.g. with a rubber hose which has been cut open).
2. Remove drive shafts on transmission side. To do this, unscrew the six hexagon socket head bolts joining each drive shaft and transmission flange. Counter at the brake disc or activate the parking brake to avoid simultaneous turning.
Drive shaft
3. Pull off electric connector for reversing-light switch.
Reversing-light switch
4. Lever off shift cable (with grey sealing cap) -1- and selector cable (with blue sealing cap) -2- from ball pin and detach from supports.
Shift and selector cables
Removing transmission
Danger: If the supports are folded down, the vehicle will roll off the platform lift when it is lowered.
--> Ensure that the platform is prevented from lowering.
--> Remove supports before lowering.
Information: The fastening nuts of the transmission support must never be loosened at the hydraulic mount because otherwise the transmission brackets will be damaged.
1. Place transmission jack under the transmission and secure retaining strap.
2. Remove crossmember.
Cross member
3. Unscrew fastening screws between the transmission and transmission support.
Transmission support
4. Unscrew fastening screws between the body and hydraulic mount -Arrow- and remove transmission support with hydraulic mount.
A - Transmission support
B - Hydraulic mount
C - Fastening nut (never loosen)
Transmission support
5. Lower the transmission for better access when removing the clutch slave cylinder.
6. Unscrew fastening nut on exterior shift.
Fastening nut
7. Pull exterior shift off the shifting shaft using pole terminal pull-off device Nr.99 or puller 9736.
Pulling off the exterior shift
Information: The clutch pedal must not be pressed if the clutch slave cylinder has been removed. Danger of injury from the push rod which can be pressed out of the slave cylinder hydraulically. Affix a warning note in the vehicle!
8. Unscrew fastening screw between the clutch slave cylinder and transmission and remove clutch slave cylinder. Do not disconnect clutch line while doing this.
Clutch slave cylinder
9. Unscrew fastening screws -1 to 8- and remove transmission by pulling it back and down.
Engine/transmission mount
Installing transmission
Installing transmission
Information: Before installing the transmission, clean splines of transmission input shaft and grease lightly, e.g. with Olista Longtime 3 EP.
1. Move in transmission and screw in fastening screws -1 to 8-.
Fastening transmission to engine
Information: Before installing the clutch slave cylinder, grease the push rod with Kluberalfa in the area of the release-lever ball socket. Part No. 000.043.304.02 (50g tube).
2. Insert clutch slave cylinder in transmission opening and screw in fastening screw.
Clutch slave cylinder
3. Fit the external shift mechanism and tighten nut.
Fastening nut
4. Fit left and right transmission supports with hydraulic mount.
5. Install crossmember.
Cross member
6. Remove transmission jack.
Assembly work
1. Engage shift cable (with grey sealing cap) -1- and selector cable (with blue sealing cap) -2- in the support and press on the ball pin.
Shift and selector cables
2. Push on electric connector for reverse gear switch.
Reversing-light switch
3. Fit drive shafts on the transmission side. For this purpose, tighten six hexagon socket screws between the drive shaft and the transmission flange, respectively. Counter at the brake disc or activate the parking brake to avoid simultaneous turning.
Drive shaft
4. Screw in fastening screws between anti-roll bar and rear axle carrier side member.
Anti-roll bar
Subsequent work
Subsequent work
1. Retaining device 9624/3 must be removed from the crossmember.
Special tool
2. Fit restraining cables to crossmember.
3. Install support plate.
4. Install rear silencer.
5. Mount wheels.
6. Check transmission oil level and top it up, if necessary.
7. Lower the vehicle.