Removing Gearbox Side Cover
Removing gearbox side cover
Special tools:
998 5972 JACK 998 5972 Jack
999 5460 Lifting hook 999 5460 Lifting Hook
999 5716 Reading off tool 999 5716 Reading Off Tool
999 5736 Wrenches 999 5736 Wrenches
999 5972 FIXTURE 999 5972 Fixture
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.
Disconnecting the battery lead
See Battery, disconnecting Battery Disconnecting. It is essential that the instructions are followed.
Removing engine compartment components
Removing the air cleaner (ACL) housing
Brake pipe master cylinder / ABS unit, replacing Brake Pipe Master Cylinder / ABS Unit, Replacing.
Applies only to turbocharged cars
Carefully heat around the pipe at the charge air cooler (CAC). Use a hot air gun. Loosen and remove the pipe.
Removing the upper torque rod
Remove:
- the plastic covers over the spring strut mountings (applies only to early versions)
- the screws
- the screw and nut for the engine mounting.
Collecting gearbox fluid
Use an oil suction unit.
Remove the dip stick.
Extract all the fluid (6 liters). This is done to avoid oil spillage when the cover is removed.
Removing the charge air pipe and hose
Remove the charge air pipe and the cooler hoses.
Removing the spark plugs cover
Remove the spark plug cover.
Installing lifting fixture
Remove the 2 screws at the engine mounting.
Install the lifting eye 999 5717 Lifting eye 999 5717 Lifting Eye.
Disconnect the ground strip.
Removing the connector from the gearbox
Remove:
- the screw for the clamp holding the positive cable on the engine
- the connector from the gearbox (press the connector together). Pull it from the gearbox.
Remove the cable from its clips on the side member.
Installing the lifting beam and lifting hook on the engine lifting eyelet
Install the lifting beam and the lifting hook on the engine lifting lugs.
Disconnecting the front suspension components
Remove the front end components.
Removing the screws from the cable conduit and the parking heater. Removing the ground lead bracket from the sub-frame
Remove:
- the screw for the front engine pad (see the arrow)
- the screws for the torque rod in the gearbox.
Applies only to cars with parking heaters:
Remove the fuel line from its clips on the sub-frame.
Hang up the parking heater in a tie strap.
Removing the ball joint nut (left hand side)
Remove the ball joint nut (left hand side).
Removing the control arms for the anti-roll bar, the track rod and the screw from the drive shaft on the left hand side
Only slacken off the brake pipe bracket on the left-hand side.
Remove the control arms for the anti-roll bar, the track rod and the screw from the drive shaft on both sides.
Removing the screws from the sub-frame support plates (both sides)
Remove the screws from the sub-frame support plates (both sides).
Removing the pipe lines from the sub-frame
Unhook the servo pipe and the evaporator pipe from the holders on the right-hand side of the sub-frame. Unhook the servo pipe from the clip on the sub-frame.
Removing the stub axle from the control arm
Remove the stub axle from the control arm.
Pressing up the sub-frame on the right-hand side
Press up the sub-frame on the right-hand side.
Removing the front cross member
Remove the front cross member.
Removing the bracket for the heated oxygen sensor (HO2S) wiring
Remove the screws for the bracket in the sub-frame holding the heated oxygen sensor (HO2S) cable. Push the bracket to one side.
Preparatory work for removing the stub axle on the left-hand side
Removing the drive shaft from the stub axle (left-hand side)
Remove the drive shaft from the stub axle.
Removing the left drive shaft from the gearbox
Use pry bars 999 5736 Wrenches 999 5736 Wrenches (two bars).
Note! Do not damage the seal.
Note! Do not under any circumstances pull the drive shaft in such a way that could cause the joints to separate. The joints do not have axial pinions.
Removing the nuts and screws for the steering gear sub-frame
Remove the nuts and screws.
Removing the collision protection system over the steering gear
Applies only to right-hand drive cars
Remove the collision protection system.
Lowering the sub-frame
Use the mobile jack. Lower the sub-frame approximately 5 cm.
Hang up the steering gear in a tie strap.
Carefully lower the sub-frame. Let it hang free.
Note! Ensure that the screws for the steering gear release from the frame.
Removing the screw for the rear engine mounting
Remove the screw for the rear engine pad.
Removing the rear engine mounting
Remove the rear engine mounting.
Preparations for removal of the gearbox side plate
Preparatory work can be carried out when the vehicle is lowered.
Remove the 2 nuts from the wing liner. Angle out and tie up the wing liner to the lifting beam. Use a retaining strap.
Note! Do not damage the front wing.
Removing the oil pipes from the gearbox
Remove the oil pipes.
Lowering the engine and gearbox
Caution! Do not damage the exhaust boots.
Lower the engine and gearbox.
Preparations for removal of the gearbox side cover
Blow clean thoroughly around the gearbox.
Collect the oil spill when the side cover has been removed.
Remove the nut for the clamp and the bracket holding the wiring.
Cut off the tie straps (2) holding cable harness above the bracket. Push the wiring to one side to access the screw.
Remove the screw and the bracket.
Remove all the screws from the side cover (the lower 5 screws are Torx screws).
Caution! Ensure that the lower and outer screws align correctly during installation.
Removing the gearbox side cover
Pull out the side cover slightly from the gearbox.
Angle out the cover at the front on the left side quite a lot. Pull the cover backwards to the steering gear.
Pull out the cover at the bottom edge so that the upper section passes the side member.
Finishing work
Note! The gasket may only be re-used once. Check whether there is a 2 at the top of the right-hand corner of the gasket. The gasket must be replaced if there is a 2 on it. If there is no digit, stamp a 2. This indicates that the gasket has now been reused and must be replaced the next time the side cover is removed. Make this mark to assist other mechanics.
Replace the old rubber gasket which seals around the drive shaft.