Removal and Replacement

Removing and refitting transmission








Preliminary work

1. Remove engine-transmission unit.

Removing transmission

1. Disengage starter cable on the right air flange.
2. Disconnect pressure line from clutch slave cylinder.





Pressure line

3. Unscrew fastening screws for slave cylinder.





Slave cylinder threaded joint

4. Hang slave cylinder on the engine without tension.
5. Remove the left air flange.





Left air flange

6. Unscrew hexagon-head bolt for holder -A- and pull out bearing cover -B- using pliers.





Clutch control shaft mount

7. Screw a screw (M6) into the clutch control shaft and pull out the shaft at the screw.





Pulling out clutch control shaft

8. Attach transmission to workshop crane.
9. Unscrew connecting bolts between the engine and transmission and pull out the transmission to the rear.

Refitting transmission

Caution
Components can become jammed!
^ Malfunction in clutch system/starter

- Insert cap for TDC sender at the correct position. Once you have refitted the transmission, check the position of the cap again and adjust it if necessary.

Information
^ Grease teeth on the drive shaft with a very thin coat of Olista Longtime 3P (only as protection against corrosion).

1. Insert release lever into the release bearing and fix in installation position with adhesive tape.





Release lever

2. Insert cap for pulse sender at the correct position in the transmission housing.





Cap

3. Attach transmission to workshop crane.
4. Refit transmission and screw in connecting bolts. Ensure that the cap -A- is seated correctly when doing so.





Check the installation position of the cap.





5. Fit release lever shaft with sealing rings.





Overview of clutch control shaft

1 - Hexagon-head bolt
2 - Holder
3 - Bearing cover
4 - Needle-roller bearing with assembly bore
5 - Sealing rings
6 - Clutch control shaft
7 - Release lever

6. Remove adhesive tape through the assembly opening in the release fork.
7. Fit needle-roller bearing.
8. Fit bearing cover using special tool removal mandrel 9287.





Holder for clutch control shaft

9. Fit holder for clutch control shaft.





10. Fit left air flange.





Left air flange





11. Install slave cylinder.





Slave cylinder threaded joint





12. Fit pressure line on slave cylinder.





Pressure line





13. Engage starter cable on the right air flange.

Subsequent work

1. Install engine-transmission unit.