Transmission, Installing
Transmission Installing
Notes:
^ Secure all hose connections with hose clamps of the same type as those fitted at the factory.
Refer to Parts Supplier
^ Replace seals and gaskets.
^ Replace seals and sealing rings.
- Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease G 000 100 to the splines.
- The clutch disc must move freely back and forth on input shaft.
- Check whether dowel sleeves for aligning engine/transmission are fitted in cylinder block, install if necessary.
- Check clutch release bearing (with hydraulic actuator) for wear, replace if necessary.
- Ensure that the intermediate plate is correctly positioned on engine.
- Incline transmission to left via spindles of transmission support 3282.
- Lift the transmission carefully and move it to the installation position with transmission support 3282.
- Push the transmission over the engine flywheel at the front side first - arrow -, and then at the bevel box side.
- Insert transmission.
- Install bracket for bevel box before fitting bolts securing transmission to engine.
- Screw in bolts - arrow 1 and - arrow 2 loosely.
- Screw in engine/transmission securing bolts accessible from below. Tightening torque.
- Tighten all bolts by hand.
- Initially tighten bolts - arrow 1 - to 3 Nm.
- Tighten bolts - arrow 2 - to 35 Nm.
- Tighten bolts - arrow 1 - to 45 Nm.
- Insert small cover plate - A - (if installed) for flywheel behind angled final drive and tighten bolt (arrow) to 10 Nm.
- Tighten bolts for engine/transmission mount on top. Tightening torque.
Notes: Use VAS5085 conductor for installing securing bolts.
- Install aggregate mounts as follows:
- Replace bolts - 1 -.
- Bolt transmission console to transmission (40 Nm 90°) with sway brace still removed.
- Replace bolts - 2 -.
- Bolt transmission console to transmission mount (60 Nm + 90°).
- Using spindle of engine/transmission support bar, raise transmission up as far as transmission support.
CAUTION!: Make sure that the transmission support and the transmission console are absolutely parallel before fitting the securing bolts. If they are not parallel, the thread will be damaged. If necessary, lift the transmission up at the rear using trolley jack.
- Fit new bolts - 2 -.
- Bolt the transmission support onto the transmission console (60 Nm + 1/4 turn = 90°)
CAUTION!: Do not remove support bar 10 222A unto all the bolts on the engine/transmission mountings have been tightened with a torque wrench.
- Remove support bar.
- Install subframe as follows:
- Move the drive axles into installation position and tighten by hand.
- Move subframe into installation position.
- Fit subframe bolts.
- Position steering box on subframe and fit steering box bolts.
- Threaded bush -1- must be properly seated in hole in subframe.
- The rubber buffer on the opposite side should fit on the corresponding projection on the subframe.
- Tighten bolts on steering box.
- Bolt on subframe using new bolts:
- Bolt drive axles to transmission (M10 Bolts; 77 Nm)
- Fit right drive axle guard (25 Nm).
- Bolt sway brace to transmission - arrows B - (40 Nm + 90°).
- Use new bolts for securing.
- Press engine/transmission assembly toward bulkhead; the guide pin on the bevel box must be guided carefully into the driveshaft flange when doing this.
Notes:
^ Take care not to damage seals in driveshaft flanges when removing and installing. If a seal is damaged the driveshaft must be replaced.
^ Ensure driveshaft is horizontal when pushing onto guide pin.
- Use new bolts for securing.
- Bolt driveshaft to flexible coupling on bevel box - arrows - (60 Nm).
- Reconnect exhaust system.
- Press the pressure pipe -1- into the hose connector and secure with the retainer arrow -.
Notes: Do not operate the clutch pedal before bleeding the clutch system.
- Remove 3094.
- Attach connector on reversing light switch - 2 -.
- Install starter and screw in lower bolt.
- Attach power steering pipe to transmission - arrows -.
- Connect pressure pipe -2- to power steering pump, using new seals (38 Nm).
- Remove 3094.
- Plug in connector -1- at power steering pressure switch.
Vehicles with 2 charge air coolers
- Install power steering pump pulley and ribbed belt.
- Install connecting pipe between the two charge air coolers.
All models
- Check oil in transmission with bevel box.
- Install noise insulation in the center and on left and right sides -arrows-.
Vehicles with 1 charge air cooler
- Install air duct at bottom of right - hand longitudinal member (air duct leads to charge air cooler). Tightening torque: 10 Nm.
All models
- Install upper securing bolt on starter.
- Plug in connector- 3 -.
- Bolt on retainer - 2 -, insert wiring and engage connector in retainer.
- Attach Ground cable- 1 -.
- Bolt sway brace onto aggregate carrier (arrows A) (20 Nm - 90°).
- Bolt Bowden cable mounting bracket onto transmission (arrows) (23 Nm).
- Install shift Bowden cable - B - with the transmission shift lever - arrow 2 -(25 Nm).
- Secure selector Bowden cable - A - with reversing lever with securing ring (arrow 1).
- Connect connector to speed sensor (arrow).
- Check for tension free installation of aggregate mounts for engine and transmission:
- Venting clutch system.
- Adjusting shift mechanism 3.
- Install battery carrier and battery.
- Install complete air filter housing.
- Install engine cover.
- Enter anti - theft coding for radio after connecting battery.
- Operator's manual
- Run windows with electrical regulators up to stop.
- Then operate all window regulator switches once again for at least 1 second in the "close" position to activate the automatic lowering/lifting function.
- Set clock.
Tightening torques
Transmission to engine
1) Bolt with threaded pin M8
A: Alignment bushing for centering
Transmission console -1- to transmission
Bolts - arrows -: 40 Nm + 90°
- Replace bolts.
Transmission console -1- to transmission mount
Bolts - arrows -: 60 Nm + 90°
- Replace bolts.
Sway brace
Bolts - A -: 20 Nm + 90°
Bolts -B -: 40 Nm + 90°
- Replace bolts.