Removing and Installing Transmission

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

Disconnect battery.





Press down interlock (1 - 4) and remove noise insulation cover.
Installation: Position noise insulation cover and press downwards until interlocks (1 - 4) are heard to engage.





Removing complete exhaust system.
Remove heat shield (1 - 2).





Remove left or right heat shields.





Remove heat shield (1) on front left axle support.
Unclip cables from Lambda oxygen sensors on crossmember and transmission.





Remove connector from reversing light switch.
Unclip cable from crossmember and transmission.





Remove impulse sensor (1), refer to Powertrain Management.





Support transmission with special tool 00 2 030 / 23 0 040 230042.





Unfasten screws and remove crossmember.

Installation:
Tightening torque, refer to Manual Transmission/Transaxle, Specifications.





Unfasten screws.

Installation:
Replace self-locking nuts.
When tightening the screws, always brace screw and tighten down nut.
This prevents the flexible coupling from being subject( to torsion stress.
Tightening torque, refer to Manual Transmission/Transaxle, Specifications.





Brace propeller shaft on center mount and loosen nuts.

Installation:
Center bearing must be aligned at right angles to propeller shaft.
For tightening torque, refer to Manual Transmission/Transaxle, Specifications.





Caution:
Do not let propeller shaft fall into joints.
Joints and rubber sleeve can be damaged on constant velocity joint.





Bend propeller shaft downwards at center bearing, remove from transmission output flange and tie up to one side with a thread or wire.





Fit special tool 11 7 310 between engine oil pan and front axle support.
Turn front wheels to right lock to ensure that center track rod is not subjected to excessive loads when transmission is lowered.
Lower transmission until engine oil pan is located on special tool 11 7310.





Lift out retainer (4).
Withdraw selector rod from joint and remove window (5).

Installation:
Grease selector rod.
Use suitable grease.





Lift out retaining clip with a screwdriver.





Withdraw bearing pin and remove selector arm.

Installation:
Grease bearing pin.
Use suitable grease
Remove clutch slave cylinder; pressure line remains connected, refer to Clutch M/T.

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





Unfasten screws.

Caution: Do not allow transmission to hang on the transmission input shaft while removing and installing, as the clutch disk will be deformed.

Pull transmission downwards and remove.

Installation:
Only fit screws in conjunction with washers.
Tightening torque, refer to Manual Transmission/Transaxle, Specifications.





Installation:
Note dowel sleeves.
Replace damaged dowel sleeves.

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





Installation
Check lubrication of transmission input shaft for sticky consistency. If grease is sticky, the clutch disk must be replaced, refer to Clutch M/T, Clutch Disc.
Check clutch disk for friction rust in taper splines and replace if necessary.
Mechanically remove old grease and lining abrasion from taper splines of clutch disk (with a cloth).
Clean spline grooves and guide spigots on transmission input shaft and apply a thin coat of grease.
The amount of grease necessary for this is approximately relative to the size of a corn kernel.
Use a suitable grease.