34351903 Removing and installing transmission
WM 343519 Removing and installing transmission
Tools
Technical values
Preliminary work
DANGER
Vehicle raised incorrectly.
- Danger of fatal injury or material damage should the vehicle fall down.
-> Raise the vehicle at the prescribed jacking points.
CAUTION
Hot components
- Risk of burns
-> Let hot components cool down.
-> Wear personal protective gear.
1. Jack and raise the vehicle at the prescribed jacking points.
-> 4X00IN01 Lifting the vehicle 4X00IN01 Lifting the vehicle
Information
- Take care to maintain access to the screws for the diagonal struts in the vicinity of the rear jacking points.
2. Remove wheels.
-> 440519 Removing and installing wheel - section on "Removing" 44051900 Removing and installing wheel
3. Remove rear silencer.
-> 263319 Removing and installing rear silencer - section on "Removing" Service and Repair
4. Remove support plate.
-> 421419 Removing and installing support plate - section on "Removing" 42141900 Removing and installing support plate
5. Remove restraining cables on cross member.
Unscrew nuts for restraining cables and remove restraining cables from the cross member.
6. Support the engine.
Special tool
Retaining device 9624/3 must be screwed to cross member. Then turn spindle upwards and support engine.
Removing transmission
Dismantling
1. Loosen fastening screws between anti-roll bar and rear axle carrier side panel and fold anti-roll bar forward.
Anti-roll bar
Information
Protect drive shafts against mechanical damage (e.g. with a rubber hose which has been cut open).
2. Remove drive shafts on transmission side. To do this, unscrew the six hexagon socket head bolts joining each drive shaft and transmission flange. Counter at the brake disc or activate the parking brake to avoid simultaneous turning.
Drive shaft
3. Pull off electric connector for reversing-light switch.
Reversing-light switch
4. Lever off shift cable (with grey sealing cap) -1- and selector cable (with blue sealing cap) -2- from ball pin and detach from supports.
Shift and selector cables
Removing transmission
DANGER
If the supports are folded down, the vehicle will roll off the platform lift when it is lowered.
-> Ensure that the platform is prevented from lowering.
-> Remove supports before lowering.
Information
The fastening nuts of the transmission support must never be loosened at the hydraulic mount because otherwise the transmission brackets will be damaged.
1. Place transmission jack under the transmission and secure retaining strap.
2. Remove cross member.
Cross member
3. Unscrew fastening screws between the transmission and transmission support.
Transmission support
4. Unscrew fastening screws between the body and hydraulic mount -Arrow- and remove transmission support with hydraulic mount.
Transmission support
5. Lower the transmission for better access when removing the clutch slave cylinder.
6. Unscrew fastening nut on exterior shift.
Fastening nut
7. Pull exterior shift off the shifting shaft using pole terminal pull-off device Nr.99 or puller 9736.
Pulling off the exterior shift
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!
8. Unscrew fastening screw between the clutch slave cylinder and transmission and remove clutch slave cylinder. Do not disconnect clutch line while doing this. -> 303019 Removing and installing clutch slave cylinder 30301900 Removing and installing clutch slave cylinder - 6-speed transmission
Clutch slave cylinder
9. Unscrew fastening screws -1 to 8- and remove transmission by pulling it back and down.
Engine/transmission mount
Installing transmission
Information
Before installing the transmission, clean splines of transmission input shaft and grease lightly, e.g. with Olista Longtime 3 EP.
1. Move in transmission and screw in fastening screws -1 to 8-.
Fastening transmission to engine
Information
Before installing the clutch slave cylinder, grease the push rod with Kluberalfa in the area of the release-lever ball socket. Part No. 000.043.304.02 (50g tube).
2. Insert clutch slave cylinder in transmission opening and screw in fastening screw.
Clutch slave cylinder
3. Fit the external shift mechanism and tighten nut.
Fastening nut
4. Fit left and right transmission supports with hydraulic mount.
5. Install cross member.
Cross member
6. Remove transmission jack.
Assembly work
1. Engage shift cable (with grey sealing cap) -1- and selector cable (with blue sealing cap) -2- in the support and press on the ball pin.
Shift and selector cables
2. Push on electric connector for reverse gear switch.
Reversing-light switch
3. Fit drive shafts on the transmission side. For this purpose, tighten six hexagon socket screws between the drive shaft and the transmission flange, respectively. Counter at the brake disc or activate the parking brake to avoid simultaneous turning.
Drive shaft
4. Screw in fastening screws between anti-roll bar and rear axle carrier side member.
Anti-roll bar
Subsequent work
1. Retaining device 9624/3 must be removed from the cross member.
Special tool
2. Fit restraining cables to cross member.
3. Install support plate.
-> 421419 Removing and installing support plate - section on "Installing" 42141900 Removing and installing support plate
4. Install rear silencer.
-> 263319 Removing and installing rear silencer - section on "Installing" Service and Repair
5. Adjust the shift and selector cables. -> 34121900 Removing and installing shift and selector cables 34121900 Removing and installing shift and selector cables
6. Mount wheels.
-> 440519 Removing and installing wheel - section on "Installing" 44051900 Removing and installing wheel
7. Check and if necessary top up transmission oil.
8. Lower the vehicle.