Removing and Installing

Remove Transmission (S5D 320Z M52TU/M54)

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

Caution: Use only the approved gear oil in this manual transmission.

Failure to comply with this requirement will result in serious damage to the transmission.

Disconnect battery.

Remove intake hood (1).

Remove microfilter housing (1) and heater bulkhead behind it.

Caution: The section "Remove reinforcement plate" contains important installation instructions.

Remove reinforcement plate.

Remove engine underguard (1).

Release screws and remove front end reinforcement.

Remove complete exhaust system.

Remove heat shield (1).

Release screws and remove exhaust bracket (1).

Support transmission with a workshop hoist.

Release screws and remove cross-member (1).

Release screws.

Installation:

Replace self-locking nuts.

Grip propeller shaft and release nuts.
Tightening torque, Center mount = 21 Nm.

Bend propeller shaft downwards at center bearing (1).

Detach propeller shaft from transmission output flange and tie back to side on vehicle underbody.

Installation:
Pull off cover tape from butylene tape on both sides.

Stick butylene tape (1) to outside of center bearing (2).

Caution:
Remove butylene tape already attached to center bearing.
Clean adhesive area on center bearing and on body.
Then coat adhesive area on body with mineral oil.
This coating with oil is necessary to facilitate insertion of the sticky butylene tape in the propeller shaft tunnel.
This prevents the butylene tape from being deformed.

Installation:
Press center bearing (2) into transmission tunnel.

Lower transmission until cylinder head touches bulkhead.

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

Caution: Position special tool so that engine oil sump is securely resting on special tool.

Tighten down knurled screws until special tool rests against engine oil sump.

Caution: Slowly relieve tension on clutch slave cylinder during removal as otherwise air will be drawn in through sealing sleeve.

Release nuts and remove clutch slave cylinder. Pressure line remains connected.

Detach locking clamp.

Pull shift rod (1) out of shift rod joint (2) and remove washers (3).

Installation:
Grease shift rod pin (4).

Large contact surface of disks (3) must rest on shift rod joint (2).

Lever spring (1) with a screwdriver out of lug (2) on housing and tilt upwards.

Remove bearing pin (1).

Installation:
Grease bearing pin (1).

Detach cable plug (1) from reverse gear switch. Detach cables from fixtures.

Support transmission with a workshop hoist.

Release screws.

Caution: Do not allow the transmission to hang off from the transmission input shaft as this will deform the clutch disk.

Pull out transmission towards rear as far as possible, turn approximately 100 counterclockwise and remove.

Installation:
Pay attention to guide sleeves (1 ... 2), replace if necessary.
Ensure correct position of cover plate.

Installation:
Remove release unit and release lever, clean and apply grease to relevant points.

Installation:
Check lubrication of transmission input shaft for sticky consistency. If grease is sticky, replace clutch plate.
Check clutch plate 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).
Then apply a thin and even coat of grease with a brush in entire area of taper splines. Also in taper groove and on guide pin.