Removal and Replacement

Remove, Install Transmission

Modification Notes:

Removing, installing

1 Disconnect ground cable from battery

NOTE: Installation: Code radio, set clock, calibrate power windows and set timer in vehicles with stationary heater.

2 Remove engine carrier with engine mount (12)

NOTE: Support transmission beforehand.

3 Remove exhaust bracket (13)

CAUTION: Replace self-locking nuts (15)

4 Remove shield
5 Detach exhaust system from supports

NOTE: Detach with a V-belt.

6 Unscrew propeller shaft (17)

CAUTION: Replace self-locking nuts.

NOTE: Unscrew propeller shaft completely and pull backwards.

7 Disconnect reversing lamp switch connector (X49/1)
8 Unscrew ground cable (20)

Danger:
- Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid
- Pour brake fluid only into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

9 Disconnect line connection (11) for clutch actuation

CAUTION: Notes on brake fluid

10 Remove cap (21) from bracket (8)

NOTE: Installation: First place upper guide of cover cap (21) in position, then clip on at the bottom. The retaining tabs must lock audibly in position.

11 Unhook selector cable (7) from bracket (8), turn nut (9) counterclockwise and remove selector cable

NOTE: Installation: Lightly grease ball joint and ensure correct seating of spacer ring (10).

12 Tie back selector cable (7)
13 Unlock and pull out safety bolt (3)
14 Detach shift rod (5) from transmission

NOTE: Installation: Lightly grease ball joint.

15 Unscrew bolts (2) on crankcase and, using lifting device, remove transmission (1) downwards at an angle.

NOTE: Installation: Check seat of dowel pins and fitted sleeves.
- In-line engine: Dowel pin at transmission (2 pins)
- V-engine: Fitted sleeve to crankcase (2 fitted sleeves).

16 Check thrust bearing and deep-groove ball bearing of crankshaft

NOTE: Check for noise, rough operation, leaks and wear, and replace if necessary.

17 Install in the reverse order
18 Inspect transmission oil level
19 Bleed clutch control
20 Inspect ease of operation of shift mechanism
- If necessary: Adjust selector cable