Removing and Installing Transmission

- Remove exhaust assembly.
- Unscrew heat shield.





- Unscrew connector (2) and heat shield (3).

Installation Note:
- Also mount holder (4).





- Unscrew joint disc on transmission.
Always replace stop nuts.





Installation Note:
Tighten nuts with a standard 17 or 19 mm wrench socket together with a torque wrench.
Tightening torque:
M10 - 8.8 grade 46 Nm (33 ft.lbs)
M10 - 10.9 grade 72 Nm (52 ft.lbs)
M12 123 Nm (89 ft.lbs)

NOTE: Only tighten nuts on flange end, whenever possible, to avoid tension in the joint disc.





Version with Integrated Vibration Damper (1):
- Vibration damper (1) is mounted On the Output flange with press-fit bolts.
- Unscrew nuts on joint disc.

NOTE: Joint disc can be pulled off only after lowering the transmission.





- Loosen threaded ring (1) several turns.

Installation Note:
Tighten threaded ring (1) with Special Tool 26 1 040 after finishing installation.
Tightening torque: 20 Nm (14.5 ft.lbs)





- Unscrew center mount.

Installation Note:
Preload center mount forward by distance (A) = 4 to 6 mm (0.157 to 0.236 in).

- Bend propeller shaft down and pull it off of centering pin.

NOTE: Don't let the propeller shaft fall into joints.

- Suspend propeller shaft from car on pieces of wire.





- Lift Out retainer (1) and take off washer (2).
- Pull Out shift rod.





- Unscrew shift console on transmission.

NOTES:
Self.locking bolts - bolts will be hard to unscrew.
Always replace bolts.
Make sure consoles are horizontal to the shift console while tightening, (shift lever noise).





Version With Shift Arm:
- Lift spring (1) off of boss (2) on case with a screwdriver and swing up.
- Pull out shaft pin.

Installation Note:
Lubricate shaft pin with Molykote Longterm 2 lightly.





- Unscrew clutch slave cylinder - pipe remains connected.

Installation Note:
Bleeder screw faces down.

- Unscrew heat shield.





- Unscrew bolts (arrows).
- Pull out speed sender (2) and reference mark sender (3).

CAUTION:
Check installed position.
Plugs must not be mixed up.
Install speed sender (2) without ring in bore (D) and reference mark sender (3) with ring (4) in bore (B).
Engine cannot be started, if plugs would be mixed up.





Installation Note:
Check 0-rings (arrows).
Install senders with Molykote Longterm 2.

NOTE: Faces of DME senders must be free of grease and dirt.





- Pull off wires on reverse gear switch and lift wire harness out of holders.
- Support transmission from underneath.





- Remove cross member (1).
- Lower transmission to the front axle carrier





- Unscrew transmission from engine.
- Unscrew Torx bolts with a Torx socket.
- Remove transmission toward rear.

Installation Notes:
Washers must be used with Torx bolts to avoid increasing the breaking-loose torque.
Give splines and guide pins a light coat of Microlube GL 261 prior to installation of the transmission.
Check oil level.

Tightening Torques:

Clutch Housing To Crankcase:
M8 21-27 Nm (15-20 ft.lbs)
M10 40-50 Nm (29-36 ft.lbs)
M12 78-86 Nm (56-62 ft.lbs)
M8 (torx bolt) 19-24 Nm (14-17 ft.lbs)

Clutch Disc To Flywheel:
Bolts 8.8 22-24 Nm (16-17 ft.lbs)
Bolts 10.9 30-35 Nm (22-25 ft.lbs)
Fillister Head Bolts 22-26 Nm (16-19 ft.lbs)

Slave Cylinder:
To Clutch Housing 24 Nm (17 ft.lbs)