Part 1
Removing and installing transmissionPreliminary work
1. Disconnect battery.
2. Raise the vehicle at the prescribed jacking points.
3. Remove underbody panel.
Removing transmission
Dismantling
1. Remove the cross member
2. Dismantle the coolant hoses and container.
3. Disconnect the electrical connection for the reversing light switch.
4. Remove the electric cable (positive lead). Do this by removing the container from the transmission -arrows- and disconnecting the lead in the B-Plus box -1-.
5. Disconnect shift -1 -and selection cables -2-from the transmission.
Note: Protect drive shafts against mechanical damage (e.g. with a rubber hose which has been cut open).
6. Remove drive shafts on transmission side. To do this, unscrew the six Allen screws joining each drive shaft and transmission flange. In order to stop the wheel being pulled round, it should be held still.
Note:
Do not hang the slave cylinder for the transmission on the hydraulic hose after dismantling but fasten it with cable clips, for example.
The clutch pedal must not be depressed when the slave cylinder for the clutch has been removed since the piston may be pushed out of the slave cylinder by hydraulic pressure. A warning panel is to be attached to the vehicle for this reason.
Since the hydraulic system for the clutch has not been opened, it is not necessary to bleed the clutch.
7. Remove the clutch slave cylinder but do not disconnect the hydraulic hose.
Removing transmission
1. Place transmission jack under transmission and fasten fixing strap.
DANGER: If the supports are folded down, the vehicle will roll off the platform lift when it is lowered.
- Ensure that the platform is prevented from lowering.
- Remove supports before lowering.
2. Place suitable support (e.g. second jack) under engine to prevent it dropping.
3. Remove transmission container.
4. Remove transmission support.
Note: The transmission can be lowered by a maximum of 25 mm to improve accessibility.
5. Unscrew fastening screws (8) between engine and transmission.
6. Move the transmission out downwards and towards the front by lowering the transmission jack step by step.
7. Attach wooden edging (approximately 180x75x25 mm) between engine and cross member. This ensures that the engine is prevented from dropping when the support is removed.
8. Remove the support from under the engine.
Installing transmission
DANGER: If the supports are folded down, the vehicle will roll off the platform lift when it is lowered.
- Ensure that the platform is prevented from lowering.
- Remove supports before lowering.
Note: When positioning the transmission, make sure that the dowel sleeves are in the correct position in the crankcase.
1. Place a suitable support (e.g. a second jack) under the engine to prevent it from dropping.
2. Remove piece of wood between cross member and engine.