Manual Transmission/Transaxle: Service and Repair

Removing and installing transmission (W11)

Special tools required:
- 11 8 401
- 11 8 402
- 23 4 010

Necessary preliminary tasks:
- Disconnect battery
- Remove intake filter housing
- Drain gear oil
- Remove front left wheel arch trim
- Remove both driven shafts with steering stub carriers
- Remove throttle assembly
- Remove suction pressure sensor
- Remove impact tubes
- Remove front axle carrier (without wheel alignment!)
- Secure engine in installation position with special tool
- Remove top engine support bracket
- Remove bottom engine support bracket

Procedure



Release screws (1).
- Remove manifold heat shield.
- Tightening torque 8 Nm




- Lower front wall and fit special tools 11 8 401 and 11 8 402.




- Remove shift cables (1) with special tool 23 4 010 from ball joints.

- Withdraw shift cables from mounting (2) and remove.




Release screws (1).
- Remove clutch slave cylinder (2) from transmission.




- Detach plug connector (1) of reversing light switch.




- Release screw (1) on turbocharger inlet and open clamp (2).
- Disconnect turbocharger intake pipe (3) from connecting pipes (4).

Note: Remove pipes at quick-release couplings.

- Release pipe of clutch slave cylinder from clips on transmission and push to one side.




- Withdraw pressure line of suction pressure sensor from mounting.
- Release screws (1) and remove mounting (2).




- Release screws (1) and remove endplate (2).
- Tightening torque 9 Nm




- Release screw (1).
- Remove wiring harness for oxygen sensors from clip (2) and remove starter motor heat shield.




- Release starter motor connections (1) and (2).
- Alternator connection on starter 14 Nm
- Engine harness to starter solenoid 8 Nm
- Remove wiring harness from transmission area.

Note: Routing of wiring harness to starter motor.




- Release screw (1).
- Release screws (2).
- Remove transmission mounting.




- Lower engine approx. 135 mm.

Note: A second person is required to help in removing and installing the transmission.

- Release transmission bolts.
- Remove transmission.