Removing and Installing Transmission

23 00 022 - Removing and installing transmission (W10)

Removing and Installing Transmission
Special tools required:
^ 00 0 201
^ 00 0 202
^ 00 0 205
^ 00 0 207
^ 00 0 209
^ 11 8 260

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

Caution:
^ Use only approved gear oil in this manual transmission.
^ Failure to comply with this requirement will result in serious damage to the transmission.

Turn off ignition.

Disconnect battery.





Remove battery box.

Remove bolts securing manifold heat shield (1).

Remove heat shield.
Manifold heat shield 8 Nm





Remove upper stabilizer bolts (1).

Remove stabilizer (2).

Unclip fuel pipe (3) and vent pipe (4) from bracket.
Upper stabilizer bracket to body mounting 100 Nm
Upper stabilizer bracket to engine mounting 100 Nm


Drain gearbox oil.

Remove front left wheel arch liner.

Remove driveshafts with knuckle carrier.





Remove lower stabilizer fixings (1).

Remove stabilizer (2).
Lower stabilizer to oil sump holder 100 Nm
Lower stabilizer to front axle 100 Nm


Remove front subframe.





Remove clips from gearshift abutment bracket (1) and release gearshift cables (2) from ball joint.

Remove gearshift abutment bracket bolts (3) and remove gearshift abutment bracket (4).
Gearshift cable abutment bracket
M8 22 Nm





Remove clutch slave cylinder fixings (1) and remove clutch slave cylinder (2) from gearbox.
Slave cylinder to bracket
M8 24 Nm





Remove reverse lamp connector (1).





Remove brake booster pipe connection from manifold and unclip from bracket.

Push circular ring down to release pipe (1).





Remove coolant pressure cap from fill tower.

Remove oxygen sensor bracket (1) and coolant pipe bolt (2).

Move coolant pipe clip (3).
Thermostat to cylinder head
M6 12 Nm
Coolant line to cylinder head
M8 25 Nm





Fit engine lift bracket special tool 11 8 260





Fit engine support bridge to vehicle.

Use special tool 00 0 201, 00 0 202, 00 0 205, 00 0 207 , 00 0 209

Tighten support bridge sufficiently to support engine and gearbox weight.





Remove gearbox mount retaining bolt (1) to upper bracket and retaining bolts (2) to gearbox.

Remove gearbox mount (3).

Lower engine approximately 40 mm.
Gearbox mount retaining bolt to upper bracket 66 Nm
Mount bracket to gearbox 38 Nm

Note: Lowering the engine excessively could damage the exhaust system.

Take care of the A/C pipe to compressor when lowering engine down.





Remove starter motor heat shield bolts (1).

Remove oxygen sensor harness from clip (2).

Remove starter motor heat shield.
Starter motor heat shield
M6 9 Nm

Pull transmission downwards and remove.





Remove starter motor connections (1) and (2).
Alternator connection on starter 14 Nm
Engine harness to starter solenoid 8 Nm

Note: Starter motor harness routing.





Remove starter motor retaining bolts (1) and remove starter motor.
Starter motor to gearbox 85 Nm





Remove closure plate retaining bolts (1) and remove closure plate bracket (2).
Closure plate retaining bolts
M6 9 Nm





Remove gearbox retaining bolts (1) and (2).

Remove gearbox.

Note: Two shorter bolts are installed into the oil pan.
Gearbox to engine retaining bolts
M12 85 Nm