23 00 017 Removing and installing transmission (GS6-17BG) N52K/N53

Special tools required:

00 2 030
00 9 010
00 9 120
00 9 130 See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .
21 2 221 See CLUTCH - SPECIAL TOOLS .
23 4 050 See MANUAL TRANSMISSION - SPECIAL TOOLS .

IMPORTANT: After completion of work, check gear oil level .
Use only the approved gear oil . See MANUAL TRANSMISSION - OPERATING FLUIDS .

Failure to comply with this requirement will result in serious damage to the manual transmission.

IMPORTANT: Aluminium-magnesium materials.
No steel screws/bolts may be used due to the threat of electrochemical corrosion.
A magnesium crankcase requires aluminum screws/bolts exclusively.
Aluminum screws/bolts must be replaced each time they are released.
The end faces of aluminum screws/bolts are painted blue for the purposes of reliable identification.
Jointing torque and angle of rotation must be observed without fail (risk of damage) .

Necessary preliminary tasks:

Disconnect battery . See 12 00... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .
Remove underbody protection and bracket at front and rear
Remove reinforcement plate
Important notes on installation are described in this work step

Remove complete exhaust system . See EXHAUST SYSTEM - REPAIR INSTRUCTIONS .

Remove heat shields (1) and (2).

Fig 1: Identifying Heat Shields

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Disconnect plug connector (1).

Release screws (2).

Remove cover plate (3).

Unscrew holder (4).

Tightening torque 23 00 1AZ . See MANUAL TRANSMISSION - TIGHTENING TORQUES .

Fig 2: Identifying Plug Connector, Screw And Cover Plate

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Installation:

Release aluminum screw on right next to cable retaining plate with special tool 00 9 010 .

Aluminum screws must be replaced. Tightening torque 23 00 2AZ . See MANUAL TRANSMISSION - TIGHTENING TORQUES .

Fig 3: Identifying Special Tool (00 9 010)

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NOTE: N53 only

Detach cable from bracket (1).

Detach plug (1) from reversing light switch.

Fig 4: Identifying Cable From Bracket

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Release cable from retainers.

Fig 5: Identifying Plug From Reversing Light Switch

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Supporting transmission:

Support transmission with special tools 23 4 050 , 00 2 030 .

Secure transmission to mounting with tensioning strap (1).

Tasks are described in ENGINE AND GEARBOX SUSPENSION - REPAIR INSTRUCTIONS .

After completion of work, check transmission oil level.

Fig 6: Identifying Special Tool And Tensioning Strap

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Remove transmission cross-member .

Fig 7: Identifying Exhaust System Bracket And Bolts

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Release bolts (1).

Remove exhaust system bracket (2).

Tightening torque 23 71 4AZ . See MANUAL TRANSMISSION - TIGHTENING TORQUES .

Release screws.

Remove transmission bearing block (1).

Tightening torque 23 71 4AZ . See MANUAL TRANSMISSION - TIGHTENING TORQUES .

Fig 8: Identifying Transmission Bearing Block And Screw

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Support engine.
Remove propeller shaft from transmission.
Release center bearing.
Tie propeller shaft to one side.

Tasks are described in Removing PROPELLER SHAFT .

Fig 9: Identifying Shift Rod And Retainer

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Lift off retainer (1).

Disconnect shift rod (2).

Installation:

Grease shift rod.

Grease, refer to MANUAL TRANSMISSION - OPERATING FLUIDS .

Make sure shims (3) are in correct position.

Fig 10: Identifying Bearing Pins

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Release and remove bearing pins (1) in direction of arrow.

Lift out shift arm (1).

Installation:

Grease bearing pins (1).

Grease, refer to MANUAL TRANSMISSION - OPERATING FLUIDS .

Fig 11: Identifying Bearing Pins

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NOTE: Pressure line of clutch slave cylinder remains connected.

IMPORTANT: Slowly relieve tension on clutch slave cylinder otherwise air is drawn in through sealing sleeve.

Release nuts (2) and remove clutch slave cylinder (1).

Tightening torque 21 52 5AZ . See CLUTCH - TIGHTENING TORQUES .

Fig 12: Identifying Nuts And Clutch Slave Cylinder

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Release screws.

Installation:

Observe screw fastening sequence without fail.

Tightening torque, steel screws 23 00 1AZ . See MANUAL TRANSMISSION - TIGHTENING TORQUES .

Aluminum screws must be replaced.

Tightening torque and angle of rotation Aluminum screws 23 00 2AZ . See MANUAL TRANSMISSION - TIGHTENING TORQUES .

IMPORTANT: Do not allow the transmission to hang off from the transmission input shaft as this will deform the clutch plate. Pull out transmission towards rear and remove.

Fig 13: Transmission Housing Bolts Tightening/Loosening Sequence

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Installation:

Secure angle of rotation special tool 00 9 120 with magnet 00 9 130 to floor plate. Screw down aluminum screws according to angle of rotation.

Angle of rotation 23 00 2AZ .

Fig 14: Identifying Special Tool (00 9 130) And (00 9 120)

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Installation:

Check that dowel sleeves are correctly seated.

Replace damaged dowel sleeves.

Ensure correct position of cover plate.

Fig 15: Identifying Dowel Sleeves And Cover Plate

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Installation:

Check lubrication of transmission input shaft for sticky consistency. If grease is sticky, clean input shaft and replace clutch plate .

Check clutch plate for friction rust in splines and replace if necessary.

Mechanically remove existing grease and lining abrasion from splines of clutch plate (with a cloth).

Fig 16: Identifying Transmission Input Shaft

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Installation:

Greasing specification:

Remove and clean release bearing and release lever .
Push on grease scraper ring 21 2 221 as far as it will go.
Grease splines (1) of input shaft with a brush. Refer to MANUAL TRANSMISSION - OPERATING FLUIDS .

Fig 17: Identifying Special Tools And Input Shaft Splines
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Detach grease scraper ring.