Remove and Replace

REMOVING AND INSTALLING TRANSMISSION

Note: After completion of the work, check transmission oil level. Refer to "Oil Change In Manual Transmission"

On vehicles with ASC+T, the throttle body and/or the expansion tank on the master brake cylinder can become damaged when the transmission is lowered.

- Remove throttle body (ASC+T).
- Disconnect battery.
- Disconnect propeller shaft from transmission flange and tie up to one side. Service and Repair




- Remove retainer (1).
- Withdraw selector rod (3) from selector linkage joint and remove washers (2).

Installation:
- Apply thin coat of grease to selector rod.




- Unfasten nuts and remove clutch slave cylinder (pressure line remains connected).

Caution! Relieve clutch slave cylinder slowly, as otherwise air will be sucked in via the sealing sleeve.

Installation:
- Tightening torque: 22 Nm




- Pull wires off reverse-gear switch. Loosen oxygen-sensor connector in holder.




- Remove cross tube.




- Attach special tool 11 8 022 to left and right control arms.

Caution! Locate special tool in such a position that engine oil pan rests securely on special tool.

- Tighten down knurled screws until special tool makes contact with engine oil pan.




- Support transmission with a workshop hoist. Unfasten screws and remove cross member with rubber mount.
- Lower workshop hoist.

Installation:
- Tightening torque: 42 Nm




- Lower engine and transmission by unfastening knurled screws until cylinder head and manifold are just above, but not in contact with, engine fire wall or heating connections (visual check).




- Secure special tool 11 8 021 to front axle support.
- Screw up stud (1) enough for it to bear on oil sump.
- (Support prevents engine from tilting forward after removing transmission.)




- Use a screwdriver to lift out spring (1) from the lug (2) on the housing and swivel upwards.
- Pull out shaft.

Installation:
- Apply thin coat of grease to bearing pin.




- Support transmission with a workshop hoist.
- Unfasten screws.

Caution! Do not allow transmission to hang on transmission input shaft when removing and installing, as the clutch disc will be deformed.

- Pull transmission downwards and remove.

Installation:
- Always fit screws with washers.
- Tightening Torque:
Hex Screws M8 25 Nm
M10 49 Nm
M12 74 Nm
Torx Bolts M8 22 Nm
M10 43 Nm
M12 72 Nm




Installation:
- Note dowel sleeves (1-2) and replace if necessary.
- Ensure correct position of cover plate.
- Remove and clean release unit and release lever and grease appropriate points.




Installation:
- Check lubrication of transmission input shaft for sticky consistency. If the grease is sticky, the clutch disc must be replaced.
- Check clutch disc for friction rust in taper splines and replace if necessary.
- Mechanically remove old grease and lining abrasion from tape splines of clutch disc (with a cloth).
- Clean spline grooves and guide spigots on transmission input shaft and apply a thin coat of grease.
- The volume of grease required for this corresponds roughly to the size of a corn on the cob.