23 00 018 Removing and installing transmission (GS6-53DZ) N54

Special tools required:

IMPORTANT: After completion of work, check GEAR OIL LEVEL .
Use only the approved gear oil.

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

IMPORTANT: Aluminium screws/bolts must be replaced each time they are released .
Aluminium screws/bolts are permitted with and without color coding (blue).
For reliable identification:
Aluminium screws/bolts are not magnetic .
Jointing torque and angle of rotation must be observed without fail (risk of damage) .

Necessary preliminary tasks:

DISCONNECT BATTERY
Remove REINFORCEMENT PLATE
Remove EXHAUST SYSTEM
Support engine with lifter

Remove heat shields (1) and (2).

Fig 1: Identifying Heat Shields

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Release bolts (1).

Disconnect connector (2).

Steel screws, tightening torque 23 00 1AZ .

Aluminium screws, tightening torque 23 00 2AZ .

Release aluminium screws with special tool 00 9 010.

Fig 2: Identifying Connector And Bolts

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Unclip cable (1) from holder.

Release screw (2) and remove holder (3).

NOTE: Illustration similar

Fig 3: Identifying Cable, Screw And Holder

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Release bolts (1).

Remove holder (2).

Fig 4: Identifying Transmission Bolts And Holder

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Disconnect plug connection (1) from reversing light switch.

Release cable from retainers.

Fig 5: Identifying Plug Connection

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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 TRANSMISSION BRACKET .

After completion of work, check transmission oil level.

Fig 6: Identifying Special Tools (00 2 030) And (23 4 050)

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Remove TRANSMISSION CROSS-MEMBER .

Release screws.

Remove transmission support block.

Tightening torque 22 32 2AZ .

Fig 7: Locating Transmission Support Block Bolts

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

Tasks are described in Removing PROPELLER SHAFT .

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 and remove clutch slave cylinder.

Tightening torque 21 52 5AZ .

Fig 8: Locating Clutch Slave Cylinder Nuts

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Lever out retainer (1).

Disengage shift rod (2).

Installation:

Grease shift rod.

Grease, refer to MANUAL TRANSMISSION - OPERATING FLUIDS .

Make sure shims (3) are in correct position.

Fig 9: Disengaging Shift Rod

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

Fig 10: Removing Bearing Pins

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Lift out shift arm (1).

Installation:

Grease bearing pins (1).

Grease,

refer to MANUAL TRANSMISSION - OPERATING FLUIDS .

Fig 11: Lifting Out Shift Arm

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Release screws.

Installation:

Tightening torque, steel screws 23 00 1AZ .

Tightening torque, aluminium screws 23 00 2AZ . Screws: 3/4/5/9/10 (screw 3 only present on N54).

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 12: 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 aluminium screws according to angle of rotation. Angle of rotation 23 00 2AZ .

Fig 13: Identifying Special Tools (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 14: Identifying Correct Position Of 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 15: Locating Input Shaft Splines

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Installation:

Greasing specification:

Remove and clean RELEASE BEARING AND RELEASE LEVER .
Push on grease scraper ring 21 2 240 as far as it will go.
Grease splines (1) of input shaft with a brush. refer to MANUAL TRANSMISSION - OPERATING FLUIDS .
Detach grease scraper ring.
Lightly grease guide sleeve for release bearing.

Fig 16: Identifying Special Tools (21 2 240) And (21 2 221)
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