Remove and Replace

Note: After completion of the work, check transmission oil level.

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), refer to Powertrain Management.
Disconnect battery.
Disconnect propeller shaft from transmission flange and tie up to one side, to Drive/Propeller Shafts, Bearings and Joints.






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

Installation:
Apply thin coat of grease to selector rod.
Use suitable grease.





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, to Clutch M/T, Specifications.





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





Remove cross tube. roadster:
Remove reinforcement bracket.





Engine M40: Remove end fire wall.
Unscrew cable duct from rear end of engine.
Mount special tool 00 0 200 and hook it into the eye on the crankcase.
Tighten spindle (1).





M50/M52 engine: Remove end fire wall.
Unscrew injection pipe cover (1).
Screw special tool 11 0 030 down through intake manifold and into bracket of crankcase.
Fit special tool 00 0 200 and attach to special tool 11 0030.
Tighten spindle (2).





M41/M43 engine: Attach special tool 11 8 022 to left and right control arms.

Caution: Locate special tool in such a position that engine oil pan rest 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, refer to Manual Transmission/Transaxle, Specifications.





M40/ M42/ M50/ M52 engine: Lower engine and transmission with spindle (2) until cylinder head and manifold are just above, but not in contact with, engine fire wall or heating connections (visual check).





M41/M43 engine: 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).





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.
Use suitable grease.





Support transmission with 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, refer to Manual Transmission/Transaxle, Specifications.





Installation:
Note dowel sleeves (1 - 2) and replace if necessary.
Ensure correct position of cover plate.

Installation:
Remove release unit and release lever and apply grease to appropriate points, refer to Clutch M/T, Throw-out Fork.





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 the taper splines of the clutch disc (with a cloth).
Clean spline grooves and guide spigots on transmission input shaft and apply a thin coat of grease.
Use suitable grease.