Removing and Installing Transmission (S5D 280Z, 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, grounding strap to body.
Remove center muffler.
Remove heat shield at front right.
Remove heat shield at rear.
Caution: Driving without reinforcement plate is not permitted.
Remove reinforcement plate.
Remove engine underguard at front.
Detach stabilizer bar and slide forwards. This operation is described in the section "Removing and installing stabilizer bar".
Remove and install front propeller shaft.
Release screws and remove exhaust bracket (1).
Release screws.
Tightening torque, refer to Specifications.
Preparing transmission mount, special tool 23 0 130:
To do so, bolt special tool 23 0 133 (3) to special tool 23 0 131 (1) and 23 0 132 (2).
Note: Observe side markings.
Support transmission and transfer case with special tool 00 2 030 and 23 0 130.
Unclip cable from transmission.
Release screws and remove cross-member (1).
Tightening torque, refer to Specifications.
Release screws.
Tightening torque, refer to Specifications.
Installation:
Replace self-locking nuts.
When tightening screws down: Grip each screw and tighten down nut. This prevents the flexible disk from being subjected to torsion stress.
Caution: Do not let propeller shaft fall into joints.
Joints and rubber sleeve can be damaged on constant-velocity joint.
Grip propeller shaft and release nuts.
Tightening torque, refer to Specifications.
Bend propeller shaft downwards at center bearing (1).
Detach propeller shaft from transmission output flange and tie back to side on vehicle underbody.
Caution: Exhaust manifold must not rest on stabilizer bar.
Lower transmission.
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.
Tightening torque, refer to Specifications.
Detach cable plug (1) from reverse gear switch.
Detach cable from fixtures.
Detach retaining clip (1).
Withdraw selector rod (2) from joint and remove washers (3).
Installation:
Grease selector rod.
Pay attention to installation position of washers (3).
Lever out spring (1) with a screwdriver from lug (2) on housing.
Tilt spring (1) upwards.
Remove bearing pin (1).
Installation: Grease bearing pin (1).
Support engine at front with a hydraulic lifter.
Caution: Do not allow the transmission to hang off from the transmission input shaft as this will deform the clutch plate.
Release screws.
Tightening torque, refer to Specifications.
Pull out transmission towards rear as far as possible, turn approximately 10° counterclockwise and remove.
Installation:
Pay attention to adapter sleeves (1 and 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 disk (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.