Transmission, Installing
Transmission, Installing
• Refer to the work procedure "Transmission, removing" for the required special tools --> [ Transmission, Removing ] Transmission, Removing.
Observe the following assembly for "checking and filling up gear oil"
- All threaded bores in which self-locking bolts are threaded must be carefully cleaned of remaining locking fluid using a tap.
- Replace self-locking bolts and nuts.
- Make sure alignment sleeves for engine to transmission are installed in cylinder block, install if necessary.
If alignment sleeves are not present, shifting difficulties, clutch problems and possibly noise in transmission (loose gear rattling) will occur.
- Make sure that intermediate plate is correctly positioned on engine.
- Clean input shaft splines and lightly lubricate with grease (G 000 100).
The clutch plate must be able to easily slide back and forth on the input shaft.
To install the transmission "0A4", the transmission support (3282) must be equipped with the adjustment plate (3282/39).
- Align arms of transmission support according to holes in adjustment plate.
- Install support elements - A - and - C - (studs (3282/29)) onto adjustment plate as shown.
- Place transmission on transmission jack.
- Align adjustment plate and transmission parallel to one another.
- Install pin (3282/29) into hole for mounting bolt of pendulum support on transmission.
- Place transmission jack below vehicle, - arrow symbol B - on adjustment plate points toward direction of travel/vehicle.
- Using spindles of the transmission support (3282), screw transmission downward in the area of the differential.
- Then carefully lift transmission, when doing so, guide right flange shaft - A - in the area of the flywheel/intermediate plate as shown.
- Using spindles of the transmission support (3282), screw transmission upward in the area of the differential.
- Lift transmission up to engine.
- Push engine forward slightly (2nd technician).
- Align transmission to installation position on engine and install.
- Insert lower engine/transmission connecting bolts and tighten to torque specification.
- After transmission is bolted to engine, remove transmission jack from transmission.
- Install small cover plate, if equipped, behind right flange shaft - A - - arrows -.
- Insert upper engine/transmission connecting bolts and tighten to torque specification.
- Install console - A - with new hex bolts on to transmission - arrows - and tighten to tightening specifications.
- Use both spindles of the engine support bridge (10 - 222 A) to align the engine/transmission in installation position.
- Install new bolts - arrows - of left assembly mounting into transmission mount and tighten to torque specification.
CAUTION!
Only remove engine support bridge (10 - 222 A) when bolts for left and right assembly mountings are tightened to torque specification.
• Install engine/transmission bearing free of tension
- Install slave cylinder and tighten bolts to specified torque --> [ (item 15) Bolt, 20 Nm ] Hydraulic System Assembly Overview, - arrow B -.
- Then install the transmission supports - arrows A - and tighten to torque specification.
- Install drive axles at transmission
- If equipped, install protective cap for right inner CV joint - arrows -.
- Install pendulum supports with new bolts - arrows A -, - B - and - C -
- Assemble exhaust system and fasten exhaust system bracket to subframe
- Install turbocharger strut - 1 - at transmission and tighten bolt - arrow - to specified torque.
- Place connector - 1 - on Back-Up Light Switch (F4).
- Install starter by inserting connector - arrow 2 - and fastening wire - arrow 3 -
- Install ground (GND) cable at upper engine/transmission connecting bolt.
- Install bracket - B - on transmission.
- Push hose/line assembly - A - into bracket - B - on the transmission.
- Install cable mounting bracket on the transmission and tighten bolts - arrows - to torque specification --> [ 6 Bolt, 20 Nm ] Service and Repair.
- Install transmission shift lever - A -.
- Tighten nut - arrow 4 - to specified torque --> [ 18 Self-locking nut, 23 Nm ] Service and Repair.
- Apply a small amount of Grease (G 000 450 02) to the transmission shift lever pins - A -.
- Connect shift cable with transmission shift lever - arrow 1 -.
Metal relay lever
- Insert relay lever - B - and secure with locking washer - arrow 3 -.
- Apply a small amount of Grease (G 000 450 02) to the relay lever pins - B -.
- Connect selector cable with relay lever - arrow 2 -.
Plastic Relay Lever
- Insert relay lever together with cable retainer.
• The tab - arrow 1 - secures relay lever
• The cable retainer must be behind tab - arrow 2 -.
- Connect selector cable with cable retainer.
Continued for all
- Adjust shift mechanism --> [ Shift Mechanism, Adjusting ] Adjustments.
- Install battery carrier, battery cover and battery
- Remove engine cover and install air filter housing
- Connect battery and observe the work procedures for after connecting the battery.
- Install lower part of the left front wheel housing liner
- Install noise insulation
Tightening Specifications
Transmission to gasoline engine
Pos. - A - Alignment sleeves for centering
Transmission at diesel engine
Pos. - A - Alignment sleeves for centering
Transmission console to transmission
- Replace bolts.
- Hand-tighten all bolts.
- Tighten bolts to torque specification.
Transmission mount to body
- Replace bolts.
- Hand-tighten all bolts.
- Tighten bolts to torque specification.
Transmission support to transmission console and transmission
- Replace bolts.
- Hand-tighten all bolts.
- Tighten bolts to torque specification.
Drive axle at flange shaft.