Removal and Replacement

343519 Installing and removing transmission G96/00 and
G96/01

Tools









Removing transmission

1. Remove underbody panels (middle and rear).

2. Remove cross member.





3. Support engine with special tool retaining device 9624/1 . To do so, remove the anti-roll bar mount and pivot anti-roll bar forwards.





4. Assemble special tool retaining device 9624/1 on the body with the anti-roll bar fastening screws and adjust pressure screw -close-up- so that the pressure disc is aligned with the crankcase.

Information
- Protect drive shafts against damage, e.g. with hose (30 mm diameter)

5. Remove drive shaft on transmission side.
6. Separate electrical connection from the back-up light switch.
7. Unclip the hydraulic line for the clutch slave cylinder at the side transmission case cover.
8. Unscrew clutch slave cylinder and suspend on side. Do not remove hydraulic line.

Information
- The clutch pedal must not be pressed if the clutch slave cylinder has been removed. Danger of injury from the push rod which can be pressed out of the slave cylinder hydraulically. Affix a warning note in the vehicle!

9. Remove switch cable from the transmission and pull it off the transmission switch and selector lever.





10. Place transmission jack under the transmission and fasten fixing strap.
11. Remove gear support.





12. Remove transmission bracket.






Information
- The transmission can be lowered by a maximum of 25 mm to improve accessibility.

13. Unscrew fastening screws (8) between engine and transmission.
14. Pull transmission to the front and lower it.


Installing transmission

1. Clean toothed wheel on the drive shaft and grease lightly, e.g. with Olista Longtime 3 EP.

Information
- When positioning the transmission, make sure that the dowel sleeve is in the correct position in the crankcase.
- Run transmission in so that the clutch slave cylinder can be fitted.

2. Run transmission in from underneath and position on engine.
3. Fit clutch slave cylinder.
Tightening torque: 23 Nm (17 ftlb.)

4. Run transmission in completely, tighten fastening screws and attach to table below.









5. Install transmission support.





Tightening torque: 65 Nm (48 ftlb.)


6. Install gear support.





Tightening torque: 65 Nm (48 ftlb.)

7. Remove transmission jack.

8. Position and secure switch cable.





9. Clip hydraulic line onto side transmission case cover.
10. Attach electrical connection to the back-up light switch.
11. Fit drive shaft on transmission side.
Tightening torque: 81 Nm (60 ftlb.)

12. Disassemble special tool retaining device 9624/1 .

13. Fit anti-roll bar.
Tightening torque: 23 Nm (17 ftlb.)

14. Install cross member.





Tightening torque: 65 Nm (48 ftlb.)

15. Check transmission oil and, if necessary, top up.

16. Install underbody panels (middle and rear).

Tightening torques