Removing and Installing Rear Cover

Removing, Installing, Disassembling and Assembling Rear Cover

(transmission installed)







Exhaust system from plug connection, shield, rear engine mount and exhaust side support
remove, install (steps 3 - 5).

Cable to kickdown solenoid valve, pulse generator or speedometer shaft
remove, install (step 6).

Propeller shaft
unscrew at universal joint flange (64), slacken clamping nut and push back, clamping nut 30-40 Nm.
Torque wrench 001 589 66 21 00,
Open-end wrench 126 589 00 01 00.

Twelve-side collar nut (62)
unscrew, screw on, 120 Nm. Engage parking lock for this step (step 9).
Wrench socket 126 589 02 09 00.

Universal joint flange (64)
pull off take off washer (65) (step 9).

Rear cover (70)
remove, install, unscrew, screw on bolts (71) for this step, 13 Nm, check gasket (72).

Radial seal (66)
press out with screwdriver, press in new seal with suitable drift.

Locking ring (68)
Take off knock out grooved ball bearing, check, knock in, install locking ring tree of play (available in thicknesses of 2.0 - 2.1 - 2.2 mm) (step 13).

Drive gear (129)
Remove, install, take off locking element (131) and remove shaft (130) for this step (step 14).

Radial seal (132)
Renew, knock in with shop-made drift (step 16).

Plastic bush (69)
(if electronic speedometer fitted) remove, install. If leaks exist, use for knocking in (step 16).

Special Tools

















Shop-made tool





Note:
The drift for knocking in should be shop-made according to the stated dimensions.


Removal and Installation

1. Jack up vehicle at the rear.

2. Check whether the transmission oil has been drained; if necessary, unscrew drain plug (4a) and drain oil.


Installation Instruction
Tightening torque of drain plug 14 Nm.
Check oil level and adjust to correct level.

3. Remove crossbar (22) with rear engine mount.






4. Unscrew exhaust support (34).

5. Detach exhaust system at rear and unscrew shield plate below the propeller shaft intermediate bearing.






6. Unscrew cable (20) at the kickdown solenoid valve (61). Remove bolt at the pulse generator (24) and withdraw pulse generator.

Note:
Detach shaft on vehicles fitted with mechanical speedometer.

7. Unscrew flexible coupling (25) on the joint flange, slacken propeller shaft clamping nut and push propeller shaft together as far as possible.


Installation Instruction
Tighten propeller shaft clamping nut to 30-40 Nm.

8. Engage parking lock.

9. Unscrew twelve-side collar nut (62) and pull off joint flange (64).






Installation Instruction
Tightening torque 120 Nm, then knock the collar into the recess on the input shaft (arrow) with a suitable drift.

10. Take off disc (65).

11. Unscrew bolts (71) and take off rear cover (70).

Attention
When removing the rear transmission cover, ensure that the kickdown solenoid valve is not damaged. It may be necessary to slacken kickdown solenoid valve and turn it slightly.






Installation Instruction

Examine gasket for signs of damage. As a rule, it may be used several times, but must not be coated with sealant. Screw in bolts (71) and tighten to 13 Nm.

Note:
Clean bolts free of grease and coat with non-hardening sealant.