Removing and Installing Transmission
Removing and installing transmission
Preliminary work
1. Disconnect the battery.
2. Raise the vehicle at the prescribed jacking points.
3. Remove underbody panelling.
4. Remove cardan shaft.
Removing transmission
Dismantling
1. Remove the cross member
Cross member
2. Dismantle the coolant hoses and container
Coolant hose to the transmission
3. Disconnect the electrical connection for the reversing light switch.
Electric plug for 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-.
Connection of B+ to the transmission
5. Disconnect shift -1- and selection cables -2- from the transmission.
Removing shift and selector cables
Information
Protect drive shafts against mechanical damage (e.g. with a rubber hose that 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.
Drive shaft
7. Disconnect hydraulic line for clutch control. Collect emerging brake fluid in a suitable container. Seal open lines with suitable plug.
Clutch line
Removing transmission
1. Unscrew fastening screws between stabilizer and engine mount, screw holding device P 9624/2 to stabilizer engine mount, turn spindle upwards and support engine.
Retaining device
2. Place transmission jack under transmission and fasten fixing strap.
3. Remove transmission container.
Transmission container
4. Remove transmission support.
Transmission support
Information
The transmission can be lowered by a maximum of 25 mm to improve accessibility.
5. Unscrew fastening screws (8) between engine and transmission.
Connecting screws
6. Move the transmission out downwards and towards the front by lowering the transmission jack step by step.
Installing transmission
Information
Before installing the transmission, clean splines of transmission input shaft and grease lightly, e.g. with Olista Longtime 3 EP.
Information
When positioning the transmission, make sure that the dowel sleeves are in the correct position in the crankcase.
1. Guide in the transmission, and screw in and tighten the fastening screws.
Connecting screws
2. Remove plug from hydraulic line of clutch control and fit the line.
Clutch line
3. Fit transmission support.
Transmission support
4. Install transmission holder.
Transmission holder
5. Release retaining strap and remove transmission jack.
6. Holding device P 9624/2 is to be removed from stabilizer-engine mount and screw stabilizer onto engine mount.
Retaining device
Assembly work
Information
Protect drive shafts against mechanical damage (e.g. with a rubber hose that has been cut open).
1. Fit drive shafts on the transmission side. To do this, screw in the six Allen screws joining each drive shaft and transmission flange and tighten screws. In order to stop the wheel being pulled round, it should be held still.
Drive shaft
2. Engage shift -1- (grey end piece) and selector cable -2- (blue end piece) into support bracket for transmission and press end pieces onto ball heads.
Connecting shift cable
3. Fit the electric cable (positive lead). Do this by fitting the holder on the transmission -arrows- and connecting cables in the B-Plus box -1-.
Connection of B+ to the transmission
4. Establish electrical connection to the reversing light switch
Electric plug for reversing light switch
5. Fit the coolant hoses and container.
Coolant hose to the transmission
6. Remove the cross member
Cross member
Subsequent work
1. Install cardan shaft.
2. Check transmission oil and, if necessary, top up.
3. Bleed the clutch hydraulic system.
4. Fit underbody panels.
5. Lower the vehicle.
6. Connect the battery.