Gearbox Installation
Gearbox, refitting
Reinstalling of gearbox F35 is shown on a car with a B234 engine, installed with turbo, Air Conditioning (AC) and Traction Control (TCS), others similar.
Important: Cables, hoses, wires etc. are secured with so called securing straps of hard plastic. After tightening, the bands are cut, leaving more or less sharp ends in the securing points. Be careful as there is a risk of cuffing your fingers on the sharp ends of the securing straps.
1. Install two locating pins 83 92 128 in the parting surface of the engine body.
2. Lower the car. Move up a hoist.
3. Hook the wire (87 92 251) on to the hoist. Position the gearbox opposite the locating pins. Push in the gearbox. If necessary, turn the engine shaft.
4. Install the middle screw in the parting surface.
5. Remove the wire and the locating pins.
6. Lift the car and install the protection plate for the gearbox.
7. Install the remaining screws in the parting surface which are accessible from below.
Tightening torque: 70 ±20 Nm (50 ±15 ft lbs)
8. Hang up the subframe and secure the two links with one screw each.
9. Turn up the subframe. Make sure that the plate in the subframe's rear corner is in its correct position. Install the screw in the engine mounting and make sure that the washers end up in their correct positions. Screw on the nut.
10. Install the two screws in the subframe's front corners.
11. Install the two screws in the subframe's rear corners.
12. Install the two screws which hold the rear link. One of the screws also holds the steering.
13. Install the two screws which hold the front link.
14. Tighten all screws in the subframe.
Tightening torque front mounting: 50 ±7 Nm (37 ±5 ft lbs)
Tightening torque rear mounting: 55 ±8 Nm (41 ±6 ft lbs)
15. Install the screw to the stay in the wheel housing.
Tightening torque 50 ±7 Nm (37 ±5 ft lbs)
16. Install the screws which hold the anti-roll bar's bearing.
17. Install the nut which holds the anti-roll bar's mounting in the wishbone.
Tightening torque 47 ±7 Nm (35 ±5 ft lbs)
18. Remove the protective cover and install the drive shaft.
19. Install the three screws which hold the ball joint on the wishbone. Use new self-locking nuts.
Tightening torque 30 ±4 Nm (22 ±3 ft lbs)
20. Install the universal joint's rubber gaiter with a new clamp.
21. Check that the gearbox is in fourth gear. Install the two screws in the gearbox's universal joint.
22. Install the battery's grounding cable to the gearbox.
CAUTION: It is very important that you do not forget the grounding. risk of fire.
23. Lower the car. Release and take away the lifting beam.
24. Install and tighten all screws in the parting surface which are accessible from above.
Tightening torque: 70 ±20 Nm (50 ±15 ft lbs)
25. Check the washer in the engine mounting and tighten the nut.
Tightening torque: 70 ±21 Nm (50 ±15.5 ft lbs)
26. Remove the clamping pliers from the slave cylinder's pressure pipe and install the pressure pipe. Install the clamp on the oil pressure pipe.
27. Reconnect the reverse light connector.
28. Reconnect the connector on the cable for the speed sensor.
29. Install the turbo pressure pipe.
30. Install the hose on the bypass valve.
31. Reconnect the connector on the temperature sensor.
32. Install the battery shelf.
33. Reconnect the connector on control module ABS.
34. Install the positive cable with the two clamps on the battery shelf.
35. Install the positive plinth.
36. Install the front distribution box.
37. Install the acceleration wire and install the locking clip in the lead-through and the locking clip on the wire.
38. Install the battery.
39. Connect the battery cables to the battery.
40. Install the positive cable to the hose (cars with TCS only)
41. Lift up the car.
42. Install the left and middle spoiler units.
43. Install the front part of the inner wing.
44. Install the edging of the wheel housing.
45. Install the left front wheel.
Tightening torque: 120 Nm (89 ft lbs.)
46. Bleed the clutch hydraulic system.
47. Check for any leakage. Check the oil level in the gearbox.
48. Test drive.