Removing and Installing

Remove Transmission (S6S 420G)

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

Caution: A breaking-in inspection including an oil change is required after 2000 km. 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.

Remove intake air manifold.

Remove heater bulkhead.

Remove fan with fan impeller.

Caution: The section "Remove reinforcement plate" contains important installation instructions.

Remove reinforcement plate.

Remove engine underguard at front.

Remove catalytic converter and intermediate pipes.





Remove heat shield (1).





Remove heat shield (1).

Remove bracket for underbody protection at rear.





Disconnect cable plug (1) from reverse gear switch and from gear detection switch (2).

Detach cable from fixtures.





Release screws.


Installation:
Replace self-locking nuts.





Grip propeller shaft and release nuts.
Tightening torque, Center mount = 21 Nm.

Bend propeller shaft downwards at center bearing (1).

Detach propeller shaft from transmission output flange and tie back to side on vehicle underbody.





Note: Pressure line remains connected. Release nuts and remove clutch slave cylinder.


Caution: Slowly relieve tension on clutch slave cylinder during removal as otherwise air will be drawn in through sealing sleeve.





Support transmission with special tool 00 2 030, 23 0 041 and 23 0 042.





Unclip cable of oxygen sensor from cross-member.

Release screws and remove cross-member (1).


Lower transmission until cylinder head touches bulkhead.

Note: Secure engine at front.





Detach locking clamp.





Pull shift rod (1) out of shift rod joint (2).
Remove washers (3).

Installation:
Grease shift rod pin (4).

Large contact surface of disks (3) must rest on shift rod joint (2).





Lever out spring (1) with a screwdriver from lug (2) on housing.

Tilt spring upwards.





Remove bearing pin (1).

Installation:
Grease bearing pins (1).






Release screws.


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

Pull out transmission towards rear as far as possible, turn approximately 10° counterclockwise and remove.





Installation:
Note position of dowel sleeves.
Replace damaged dowel sleeves.
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 disc (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