Removing and Installing Transmission

Special tools required:
^ 00 2 030
^ 11 7 360
^ 23 0 041
^ 23 0 042

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

Caution: It is absolutely essential 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 manual transmission.

Instructions for disconnecting and connecting battery.
Disconnect battery negative lead from battery and cover
Remove complete exhaust system.





Remove heat shields (1) and (2).





Remove heat shield on left and right.





Disconnect plugs 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.





Support transmission with special tool 00 2 030





Unclip cable (1) from holder (2).
Release screws and remove cross-member.





Unclip cable (1) from cable holder (2) on transmission housing.





Release screws.
Remove exhaust suspension (1).





Insert special tool 11 7 360 between left engine oil sump rib and front axle support.
Lower transmission until engine oil sump rib rests on special tool 11 7 360





Release screws.

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.

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





Caution: Do not let propeller shaft fall into joints. Joints and rubber sleeve can be damaged on constant velocity joint.





Bend propeller shaft downwards at center bearing, remove from transmission output flange and tie back to one side.





Lift out retainer (4).
Pull selector rod out of joint and remove washers (5).

Installation: Grease selector rod.




Remove retaining clip with a screwdriver.





Withdraw bearing pin and remove shift arm.

Installation: Grease bearing pin.





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





Release screws.

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: Pay attention to 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.