23 00 027 Removing and Installing Gearbox (GS6-53BG/DG)

23 00 027 - Removing and installing gearbox (GS6-53BG/DG)





Special tools required:





Necessary preliminary tasks:
- Clamp off battery
- Diesel only: Remove catalytic converter
- Drain gear oil 00 11 229 Oil Change In Manual Gearbox
- Secure engine in installation position.
- Remove transmission support bracket.
- Remove transmission mount Service and Repair
- Remove front axle carrier
- Remove left output shaft.
- Remove right output shaft.





Release clips on stop/holder (1).
Detach selector lever cable (2) from ball joint.
Release screw (3) and remove bracket.





Disconnect plug (1) for reversing light switch.





If necessary, disconnect plug connection (1) on zero gear sensor.
Detach cable (2) with holder from transmission.





Note:
Pressure line of clutch slave cylinder remains connected.

Important!
Slowly relieve tension on clutch slave cylinder otherwise air may be drawn in through sealing sleeve.
If possible, do not deflect push rod of clutch slave cylinder.
A deflection of the push rod caused by removal will cause easy escape of fluid. This escape of fluid does not mean that the clutch slave cylinder is damaged.
Replacement is therefore not necessary!

Release nuts (1) and remove clutch slave cylinder.

Tightening torque 21 52 2AZ Specifications.





Release screws (1).
Release holder (2) from engine.

Note:
Not on diesel engine (W16)





Only on diesel engine (W16)
Slacken nut (1).
Release holder (2) from engine.





Only on diesel engine (W16)
Remove stud bolts (1) on gearbox side for securing catalytic converter.





Only on diesel engine (W16)
Undo screw (1) and remove cover cap (2).





Release starter bolt (1) WAF 13 from above.
Release bolts (2) and remove starter.
Tightening torque 12 41 4AZ 12 41 Starter Motor and Mounting Parts.





Supporting transmission:
Support gearbox with special tools 23 4 150 23 4 150 Universal Transmission Bracket and 00 2 030
Support transmission from underneath.
Secure transmission with tensioning strap (3).
Tasks are described in Transmission bracket 23 .. ... Universal MINI Transmission Bracket.
After completion of work, check transmission oil level.





Note:
There is no bolt fitted at the lowermost point (1) of the transmission.

Release screws.

Tightening torque 23 00 1AZ [1][2]23 00 Transmission In General.

Important!
Do not allow transmission to hang on transmission input shaft when removing and installing, as the clutch disc will be deformed.
Pull transmission downwards and remove.





Installation:
Check dowel sleeves (1) and (2) for correct seating.
Replace damaged dowel sleeves.





Installation:
Remove grease from transmission input shaft and clean shaft.
Do not grease transmission input shaft.
Check clutch plate for friction rust in splines and replace Service and Repair if necessary.





Installation:
- If reusing the clutch:
Mechanically remove existing grease and lining abrasion from splines of clutch plate (with a cloth).
Clean clutch hub and regrease.
On new clutch plates the splines are already greased.
Refer to Service Operating Fluids
- Remove and clean release bearing and release lever Service and Repair
- Add transmission oil 00 11 229 Oil Change In Manual Gearbox.