Removing and Installing Transmission (S5D 260Z, S5D 310Z)

Remove Transmission (S5D 260Z, S5D 310Z)
Special Tools Required:
^ 00 0 200
^ 11 0 030
^ 11 2 370
^ 11 8 021
^ 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.


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





Pull wires off reverse-gear switch.

Detach oxygen-sensor plug from bracket.





Remove cross tube.

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. Install special tool 00 0 200 and attach to special tool 11 0 030.
Tighten spindle (2).

Engine M51:





Remove cover from manifold.

Secure special tool 11 2 370 on intake pipe, rear.

Install special tool 00 0 200 and attach to special tool 11 2 370.

Tighten spindle.

S50 engine:





Suspend special tool 11 8 022 from left and right control arms.

Important!: Position special tool so that engine oil sump rests securely on special tool.

Tighten down knurled screws until special tool fits tightly with engine oil sump.





Support transmission with a workshop hoist.

Unfasten screws and remove cross member with rubber mount.


Lower workshop hoist.

M50/M52 engine:





Lower engine and transmission with spindle (2).

Cylinder head and manifold must not contact engine partition wall or heating connections (visual inspection).

S50 engine:





Release knurled screws to lower engine and transmission.

Cylinder head and manifold must not contact engine partition wall or heating connections (visual inspection).

S50 engine:





Clamp special tool 11 8 021 firmly to front axle support.

Screw up stud (1) enough for it to bear on oil sump.

The support prevents the engine from tilting forwards after the transmission has been removed.





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 a workshop hoist.

Unfasten screws.






Installation:
Always fit screws with washers.

Important!: 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:
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 disk (with a cloth).
Clean and grease taper grooves and guide pin of transmission input shaft.