Removing and Installing Transmission (S5D 200G, S5D 250G)
Remove Transmission (S5D 200G, S5D 250G)Special Tools Required:
- 00 0 200
- 11 0 030
- 11 8 022
Note: After completion of work, check transmission oil level.
Note: On vehicles with ASC+T, the throttle assembly and/or the expansion tank on the master brake cylinder can become damaged when the transmission is lowered.
Remove throttle assembly (ASC+T).
Disconnect battery.
Remove exhaust system.
Unflange propeller shaft from transmission and tie up to one side.
Remove retainer (1).
Withdraw selector rod (3) from selector linkage joint and remove shims (2).
Installation:
Apply thin coat of grease to selector rod.
Release nuts, 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:
Pull wires off reverse-gear switch.
Detach oxygen-sensor plug from bracket.
Remove cross tube.
Roadster:
Remove reinforcement bracket.
Remove heater bulkhead.
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 heater bulkhead.
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 0 030.
Tighten spindle (2).
Attach special tool 11 8 022 to left and right control arms.
Caution: Position special tool 11 8 022 so that engine oil sump rests securely on special tool 11 8 022.
Tighten down knurled screws until special tool 11 8 022 contacts engine oil sump.
Support transmission with a workshop hoist.
Unfasten screws and remove cross member with rubber mount. Lower workshop hoist.
Installation:
Tightening torque, 23 71 1AZ/2AZ.
M40/M42/M50/M52 engine:
Only lower engine and transmission with spindle (2) to such an extent that cylinder head and manifold do not contact engine partition wall or heating connections (visual inspection).
M41/M43 engine:
Release knurled screws to lower engine and transmission only to such an extent that cylinder head and manifold do not contact engine partition wall or heating connections (visual inspection).
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.
Support transmission with workshop hoist. Unfasten screws.
Caution: Do not allow transmission to hang on transmission input shaft when Remove, as the clutch disc will be deformed.
Pull transmission downwards and remove.
Installation:
Always fit screws with washers.
Installation:
Pay attention to guide sleeves (1 2), replace if necessary.
Ensure correct position of cover plate.
Installation:
Remove and clean release unit and release lever and grease appropriate points.
Installation:
Check lubrication of transmission input shaft for sticky consistency.
Replace clutch disk if grease is sticky.
Check clutch disk 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 and grease taper grooves and guide pin of transmission input shaft.