Transmission, Removing
Transmission, removing
Special tools: 998 5972, 999 5716, 999 5259, 999 5460, 999 5462, 999 5463, 999 5562, 999 5972. 999 7077
Disconnecting the battery lead
Remove the battery lead.
Removing engine compartment components
Remove
- the Air Cleaner (ACL) housing assembly with the intake pipe. Pull the Air Cleaner (ACL) housing out of its mountings
- the charge air pipe above the engine. Disconnect the ground strip.
Removing the upper torque rod
Remove
- the mounting screws for the torque rod
- the screw and nut for the engine mounting and torque rod
- the engine stabilizer brace.
Removing the intake pipe from the charge air cooler (CAC)
Carefully heat around the pipe at the Charge Air Cooler (CAC). Use a hot air gun. Carefully work the pipe off.
Remove the screw from the hose clamp holding the cable harness.
Remove the vacuum hose from the clip at the Air Cleaner (ACL) bracket.
Removing the coolant hose from the heater unit
Note: The hose is too short to be left in place when lowering the engine.
Turn the quick-release connector slightly in the direction of the arrow. At the same time, pull the hose towards you.
Collect the coolant that flows out.
Blocking the hose between the brake fluid reservoir and the clutch master cylinder
Remove the retaining clip from the clutch pipe junction.
Disconnect the pipe from the junction.
Note: Seal the openings against contamination. Wipe up any spilled brake fluid.
Removing the transmission cables from the levers and mountings on the transmission
Remove
- the 3 plastic holders for the cable conduit on the transmission.
- the retaining clip for the transmission cables.
Pull straight up.
Use jimmy bar 999 7077 to detach the ball joint for the transmission cable from the lever.
Detach the casing for the transmission cables from the bracket in the transmission by pressing the locking sleeve backwards.
Lift up the transmission cables.
Tie up the transmission cables.
Disconnect the connector from the back-up (reversing) lamp switch.
Remove
- the outer lever by knocking out the pin
- the screws from the mechanical cable
- the bracket (from the transmission).
Removing the mounting screws from the transmission
Fold the cable conduit out of the way.
Fold the hoses and the cable conduit out of the way of the engine and transmission.
Remove
- the 3 screws for the transmission and engine
- the 2 screws for the starter motor
- the ignition setting sender. Pull it straight up slightly.
Installing the lifting beam and lifting hook on the engine lifting eyelet
Position lifting beam 999 5716 straight above the engine lifting eyelets.
Connect lifting hooks 999 5460
On the left-hand side: Tighten to light contact.
On the right-hand side: Leave a clearance of 5 mm.
Removing splash guards
Note: Position the front lift arms so that they do not obstruct the sub-frame support plates.
Raise the car.
Remove
- the front wheels
- the splash guard under the engine
- both the screws for the front splash guard.
Press in the cover by press in the catches at the front edge of the cover. Pull the cover backwards.
Removing components around the subframe
Remove the screw from the cable conduit.
Removing the links, the tie rod, and the screw from the drive shaft (both sides)
Remove
- the link for the anti-roll bar up at the spring strut. Counterhold using Torx 30. The rubber boot must not be twisted
- the screw for the drive shaft.
Removing the nut from the ball joint (both sides)
Remove the nut for the lower ball joint and control arm. Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut. Counterhold with Torx TX 40 at the ball joint pinion when removing the nut. This is so that the ball joint boot does not turn.
Removing the screws from the sub-frame support plates (both sides)
Preparations for removal of the wheel spindle
- position mobile jack 998 5972 (in light contact) under the right-hand side of the sub frame
- slacken off both the sub-frame screws completely. Screw the screws back in approximately 5 turns
- lower the sub-frame so that it rests on the screws and the mobile jack.
Removing the wheel spindle from the control arm
Pry the control arm with a crowbar. At the same time, lift the wheel spindle off the control arm.
Note: Install socket 999 5562 on the wheel spindle ball joint. Do not damage the rubber bellow for the ball joint.
Removing the drive shaft from the wheel spindle (right-hand side)
Take hold of the drive shaft.
Pull it down towards the control arm so that it does not tension. Pull the brake disc outwards. At the same time, pull on the constant velocity joint towards the transmission so that the drive shaft loosens.
Allow the drive shaft to lie on the control arm.
Removing the sealing ring for the CV joint housing
Remove the sealing ring for the constant velocity joint housing.
Removing the cap for the drive shaft support bearing
Remove the screws from the bearing cap.
Removing the drive shaft
Take hold of the inner constant velocity joint.
Pull the drive shaft straight out of the transmission.
Note: Do not damage the seal.
Note: Do not under any circumstances pull the outer section of the drive shaft in such a way that could cause the joints to separate. The joints do not have axial pinions.
Pressing up the sub-frame on the right-hand side
Press up the sub-frame on the right-hand side
Tighten the sub-frame screws to light contact.
Then slacken off the screws approximately 4-5 turns.
Note: This is because the sub-frame hangs down more on one side.
Move the mobile jack to the left hand side.
Removing the nuts and screws for the steering gear sub-frame
Unhook the servo pipe and the evaporator pipe from the holders on the right-hand side of the sub-frame. Unhook the servo pipe from the clip on the sub-frame.
Removing the screws for the torque rod from the transmission
Remove the screw for the front engine pad.
Removing the cross members
Remove
- the screws for the cross members
- the screws for the rubber mounting in the front cross member
- the brake pipe from its holders.
Removing the bracket for the power supply cable for the heated oxygen sensor (HO2S) from the sub-frame
Remove the screw from the bracket.
Removing the left drive shaft from the transmission
Use jimmy tool 999 5462.
Note: Do not damage the seal.
Note: Do not under any circumstances pull the drive shaft in such a way that could cause the joints to separate. The joints do not have axial pinions.
Note: Applies only to cars with parking heaters: Remove the nuts for the heater from the sub-frame. Hang the heater on the left front fender.
Removing bevel gear
Only applies to cars with bevel gear
Remove the bevel gear.
Lowering the sub-frame
Use the mobile jack. Lower the sub-frame approximately 3 cm.
Hang up the steering gear in a tie strap.
Carefully lower the sub-frame. Let it hang free.
Note: Ensure that the screws for the steering gear release from the frame.
Removing the collision protection system over the steering gear
Right-hand drive cars only:
Remove the screws and nut from the collision protection system.
Note: Carefully check that the collision protection system under the steering gear is free and not under stress.
Removing the screw for the rear engine pad
Lift up the anti-roll bar mounting. Use a jimmy bar. This will make it easier to position the tool and remove the screw.
Removing the rear engine mounting
Remove the 3 screws.
Lower the car
Lowering the engine and transmission
Lower the engine and transmission on the lefthand side with the hook.
Lower the engine so that the distance between the lower edge of the mounting bracket and the spark plug cover is 250 mm.
Raise the car
Preparations for removal of the transmission
Remove the 2 nuts from the fender liner. Pull the fender away from the screws.
Drill out the 4 blind rivets in the front edge of the left fender liner.
Tie up the fender liner.
Installing the fixture on the mobile jack
Install fixture 999 5463 on fixture 999 5972. Use the fixture and plate together with mobile jack 998 5972.
Locate the fixture against the transmission. Use support plate 9995463-2.
Tighten the fixture with the two torque rod screws.
Apply the mobile jack lightly against the transmission.
Removing the transmission
Remove all 7 screws securing the transmission to the engine.
Pull the transmission straight out in relation to the engine.
Note: Lower the transmission slightly when removing, so that the it passes the side member.
Continue pulling the transmission straight out.
Note: It is vital that the above instructions are followed when removing the transmission from the engine. Otherwise the center of the clutch driven plate may buckle.