Removing and Installing Transmission
Removing and installing transmissionTools
Preliminary work for transmission
1. Disconnect battery.
2. Remove centre console cover.
3. Remove shift lever knob.
4. Remove engine guard.
5. Remove rear cardan shaft.
6. Remove front cardan shaft.
7. Remove the starter.
8. Remove clutch slave cylinder.
Preliminary work for transmission
1. Disconnect battery.
2. Remove centre console cover.
3. Remove shift lever knob.
4. Remove engine guard.
5. Remove rear cardan shaft.
6. Remove front cardan shaft.
7. Remove clutch slave cylinder.
Removing transmission
Note:
^ The cables do not have to be separated from the transmission in order to remove the transmission.
Over View Of Transmission:
1. Remove insulating mat.
2. Unscrew fastening screws for securing bottom section of gearshift bracket to body.
3. Unscrew coolant pipe fastening screws on converter bell housing.
Note:
^ When removing the transfer box, support manual transmission with a wooden block on the suspension subframe.
4. Remove transfer box.
5. Support manual transmission with special tool plate and transmission jack.
6. Unscrew fastening screws for securing transmission to engine. This involves unscrewing four screws on the engine side and six on the transmission side.
7. Push out transmission. Pull off vent line for the transfer box.
8. Remove circlips on support on the transmission.
9. Remove shift and selector cables from support using special tool removal tool, universal nr.21. Remove selector support with cables.
Removing transmission
Note:
^ The cables do not have to be separated from the transmission in order to remove the transmission.
1. Remove insulating mat.
2. Unscrew fastening screws for securing bottom section of gearshift bracket to body.
3. Remove reference mark sender on the transmission bell housing.
4. Unscrew coolant pipe support threaded joint on the transmission bell housing.
5. Pull off cable plug for neutral switch.
6. Pull off cable plug for back-up light switch.
7. Remove transfer box
8. Remove breather pipe. To do so, undo the fastening screws -1 and 2- on the transmission.
9. Support manual transmission with special tool plate and transmission jack.
10. Unscrew fastening screws -arrows- for securing transmission to engine.
11. Push out transmission. Pull off vent line for the transfer box.
12. Remove circlips -inset- on support on the transmission.
13. Remove shift and selector cables from support using special tool removal tool, universal nr.21. Remove selector support with cables.
Installing transmission
Note:
^ If available: remove assembly aids from production on bottom section of gearshift bracket-arrow-. These were only needed for the first installation in order to align the gearshift bracket.
Overview Of Transmission:
1. Fasten the shift and selector cables to the ball head joint on the support.
2. Install circlips -inset- on support on the transmission.
3. Raise manual transmission with special tool plate and transmission jack.
4. Run in transmission. Connect vent line for the transfer box.
5. Screw in fastening screws for securing transmission to engine. This involves screwing in four screws on the engine side and six on the transmission side. Tightening torque: 59 ftlb. Tightening torque: 59 ftlb. Tightening torque: 59 ftlb. Tightening torque: 33 ftlb. Tightening torque: 59 ftlb. Tightening torque: 59 ftlb.
6. Support transmission with a wooden block on the suspension subframe.
7. Remove special tool plate 9725.
8. Insert gearshift bracket into the opening in the centre tunnel from below.
9. Install transfer box
10. Screw in coolant pipe fastening screws on converter bell housing.
11. Screw in fastening screws for securing bottom section of gearshift bracket to body. Tightening torque: 18 ftlb.
12. Insert insulating mat.
13. Fit centre console trim.
Installing transmission
Note:
^ If present: Remove assembly aids from production on the bottom section of the selector console-arrow-. These were only needed for the first installation in order to align the shift console.
1. Fasten the shift and selector cables to the ball head joint on the support.
2. Install snap rings -enlarged view- on support bracket on the transmission.
3. Raise manual transmission with special tool plate and transmission jack.
4. Run in transmission. Connect vent line for the transfer box.
5. Screw in fastening screws for securing transmission to engine. Tightening torque: 59 ftlb.
6. Support transmission with a wooden block on the suspension subframe.
7. Remove special tool plate 9725.
8. Install breather pipe. To do so, screw in the fastening screws -1,2- on the transmission. Tightening torque: 17 ftlb. Tightening torque: 6.5 ftlb.
9. Install transfer box. Insert gearshift bracket into the opening in the centre tunnel from below.
10. Attach cable plug for back-up light switch.
11. Push on cable plug for neutral switch.
12. Screw in fastening screws for coolant pipe support to the transmission bell housing.
13. Install reference mark sender on the transmission bell housing.
14. Screw in fastening screws for securing bottom section of gearshift bracket to body. Tightening torque: 18 ftlb.
15. Install insulating mat.
16. Install centre console trim.
Subsequent work for transmission
Touch up for transmission
1. Install clutch slave cylinder.
2. Install the starter.
3. Install front cardan shaft.
4. Install rear cardan shaft.
5. Fit engine guard.
6. Install shift-lever knob.
7. Connect battery.
Touch up for transmission
1. Install clutch slave cylinder.
2. Install front cardan shaft.
3. Install rear cardan shaft.
4. Fit engine guard.
5. Install shift lever knob.
6. Connect the battery.