Removing and Installing Transmission (S6S 420G)

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

Caution: It is necessary after 2000 km to carry out a breaking-in inspection including an oil change. Transmission must be filled with Lifetime oil! Use only the approved gear oil in this transmission.

Disconnect battery.

Disconnect battery negative lead from battery and cover.

Detach fan.

Remove complete exhaust system.

Remove underbody protection.

Remove heat shields.





Disconnect plug from reversing light switch (1) and gear detection switch (2).





Note: Pressure line of clutch slave cylinder (2) remains connected.

Release screws (1).
Tightening torque, refer to Specifications.

Caution: Slowly relieve tension on clutch slave cylinder (2) as otherwise air will be taken in through sealing sleeve.

Remove clutch slave cylinder (2) and tie to one side.

Note: Remove and install speed sensor.

Unclip cable from cable holder on transmission housing.





Remove stabilizer links from stabilizer bar.
Swivel stabilizer bar upwards.





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.





Grip propeller shaft at center bearing and release nuts.

Tightening torque, refer to Specifications.

Installation:
Center bearing must be aligned at right angles to propeller shaft.





Support transmission with special tool 00 2 030.





Unclip cable (1) from holder (2).

Release screws and remove cross-member.

Tightening torque, refer to Specifications.





Release screws.

Remove exhaust suspension (1).





Bend propeller shaft downwards at center bearing. Remove propeller shaft from transmission output flange and tie to one side with cord or wire.





Caution: Do not let propeller shaft fall into joints.

Joints and rubber sleeve can be damaged on constant-velocity joint.





Lift out retainer (4).

Pull selector rod out of joint and remove washers (5).

Installation:
Grease selector rod.

Grease, refer to Specifications.

Lower transmission until engine oil sump rests against buffer of front axle.





Remove retaining clip with a screwdriver.





Withdraw bearing pin and remove selector arm.

Installation:
Grease bearing pin.

Grease, refer to Specifications.





Support transmission with special tools 00 2 030/23 0 041 /23 0 042.





Release screws.
Tightening torque, refer to Specifications.

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

Pull out transmission towards rear and remove.

Installation:
Install screws only in conjunction with washers.

Installation:





Note dowel sleeves.

Replace damaged dowel sleeves.

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 taper splines of clutch plate (with a cloth).

Then use a brush to apply a thin even coating of grease for lubricating taper splines over the entire area. Also in taper groove and on guide pin.