343519 Removing and installing transmission
WM 343519 Removing and installing transmission
Tools
Technical values
Preliminary work
1. Disconnect the battery. => 2706IN Work instructions after disconnecting the battery
2. Raise the vehicle at the prescribed jacking points. => 4X00IN01 Lifting the vehicle
3. Remove underbody panelling. => 519419 Removing and installing cover for rear underbody - section on "Removing"=> 519319 Removing and installing cover for centre underbody - section on "Removing"
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
Information
The transmission can be lowered by a maximum of 25 mm to improve accessibility.
DANGER
Vehicle can fall down
- Risk of squashing or crushing
- Risk of damage to the vehicle
-> Do not place any solid objects under the raised vehicle.
-> Ensure that the lifting platform is prevented from lowering.
-> Remove solid objects before lowering the vehicle.
-> Raise the vehicle only at the take-up points provided.
-> The outer take-up points should be used primarily.
1. Position unit elevating platform -1- under the vehicle, secure retainer plate 9769 ( -2- ) on the unit elevating platform and insert the mounting pegs of the retainer plate 9769 into the mounting bores on the engine and press in with a slight degree of pretension. The unit elevating platform must be positioned slightly diagonally using the adjustment controls so that the bores are directly parallel.
Supporting engine with a unit elevating platform
2. Place transmission jack -4- under the transmission and fasten the retaining strap.
3. Remove transmission holder.
Transmission holder
4. Remove transmission support.
Transmission support
5. Remove pulse sender from the transmission bell housing.
CAUTION
Mechanical overload of components
- Component will be damaged irreparably
-> Observe guidelines for assembly and disassembly
Information
When you loosen the flange screws between the transmission and engine, the screws -1 and 2- must first be loosened and unscrewed. If this is not done, the engine housing can be damaged irreparably.
Flange screws
6. Unscrew the two bottom fastening screws between the engine and transmission.
7. Unscrew the remaining fastening screws.
8. Move the transmission out downwards and towards the front by lowering the transmission jack step by step.
Installing transmission
DANGER
Vehicle can fall down
- Risk of squashing or crushing
- Risk of damage to the vehicle
-> Do not place any solid objects under the raised vehicle.
-> Ensure that the lifting platform is prevented from lowering.
-> Remove solid objects before lowering the vehicle.
-> Raise the vehicle only at the take-up points provided.
-> The outer take-up points should be used primarily.
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. Run in transmission.
CAUTION
Mechanical overload of components
- Component will be damaged irreparably
-> Observe guidelines for assembly and disassembly
Information
Always replace flange screws.
When you screw in and tighten the flange screws between the transmission and engine, the screws -1 and 2- must be screwed in and tightened last. If this is not done, the engine housing can be damaged irreparably.
Flange screws
2. Screw in and tighten the four top fastening screws.
3. Screw in and tighten the two bottom fastening screws.
4. Fit pulse sender at the transmission bell housing. => Tightening torque: 10 Nm (7.5 ftlb.)
5. Remove plug from hydraulic line of clutch control and fit the line.
Clutch line
6. Fit transmission support.
Transmission support
7. Install transmission holder.
Transmission holder
8. Release retaining strap and remove transmission jack.
9. Lower the unit elevating platform and remove it.
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. Check transmission oil and top up if necessary. => 340101 Checking transmission oil
2. Bleed the clutch hydraulic system. => 300107 Bleeding the clutch system
3. Adjust the shift and selector cables. See "Securing selector cable". => 341219 Removing and installing shift and selector cables
4. Fit underbody panelling. => 519319 Removing and installing centre cover - section on "Installing"=> 519419 Removing and installing rear cover - section on "Installing"
5. Lower the vehicle.
6. Connect the battery. => Work instructions after disconnecting the battery