AR26.10-P-0020P Remove/Install Transmission

Remove and Install Transmission
- Without CODE (424) Sequentronic Transmission












CAUTION: See notes on self-locking nuts and bolts.

DANGER:
- Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries
- No fire, sparks, naked flames or smoking Wear acid-resistant gloves, clothing and goggles Pour battery electrolyte only into suitable and appropriately marked containers.

1 Disconnect ground cable of battery
2 Remove air cleaner.
- Engines 111, 112

NOTE: Installation: Grease the rubber guides lightly for assembly

3.1 Detach lower engine compartment paneling
3.2 Remove bottom sections of noise encapsulation
4 Remove rear exhaust system
5 Remove exhaust bracket (13)

NOTE: to do this, unscrew the bolts (14) on the transmission and unscrew nut (15) on the exhaust.

6 Remove screws (21)
- Model 209

NOTE: Observe installation position of refrigerant line (22)

7 Dismantle front propeller shaft from transmission.

NOTE:
- The flexible coupling remains on the propeller shaft
- Installation: Mount the front propeller shaft on the transmission

8 Loosen fitted sleeves of flexible coupling and push back propeller shaft
9 Separate plug connection of reversing light switch (X49/1)

DANGER:
- Risk of poisoning from swallowing brake fluid. Risk of injury from brake fluid coming into contact with skin and eyes.
- Pour brake fluid only into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

10 Disconnect connector (11) for clutch actuation.

NOTE: Seal lines with fitted plug.

CAUTION: Brake fluid notes.

11 Support transmission
12 Detach ground line (20) from engine mount

NOTE: To do this unscrew bolt (16)

13 Remove engine support with engine mount (12)

NOTE: Do not detach the engine mount from the engine support

14 Unlock and pull out safety bolt (3).
15 Pry shift rod (5) on transmission off ball head.

NOTE:
- Do not damage the shift rod (5) and ball head on the transmission (1)
- Installation: Grease ball joint lightly

16 Remove cap (18) on bracket (8)

NOTE:
- Installation Insert upper guide of cap (18) first, then clip in at the bottom
- Installation: The retaining lugs must latch audibly

17 Disconnect selector cable (7) from bracket (8)

NOTE: Installation Grease ball joint lightly

18 Turn nut (9) counterclockwise and remove selector cable
- Model 203

NOTE:
- Installation: Grease ball joint lightly and ensure that the spacer ring (10) is seated correctly.
- Installation: The spacer ring only serves as an assembly aid. It does not affect the functioning of the gearshift system

19 Tie selector cable (7) out of the way
20 Unscrew lead pipe from oil pan

21 Unscrew screw (2)
22 Turn lead pipe down out of the way
- Engine 111, 112, 611, 612

23 Remove transmission (1) downwards at an angle using lifting equipment
24 Check thrust bearing and deep-groove ball bearing of crankshaft


NOTE: Check for noise, rough operation, leaks and wear, and replace if necessary.

25 Install in the reverse order

NOTE: Ensure that wiring looms are routed correctly.

26 Inspect transmission oil level

NOTE:
- Correct oil level = 10 mm below bottom edge of filler hole.
- Carry out measurement e.g. with angled hexagon socket wrench.

27 Bleed clutch actuation
28 Check gearshift for ease of movement
- if necessary, adjust selector cable

29 Perform basic programming
30 Read out fault memory with STAR DIAGNOSIS and erase if necessary
31 Perform function check