23 00 019 Removing and installing transmission (GS6-37BZ) AWD

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 .

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

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  See 31 10 010 REMOVING AND INSTALLING/REPLACING REINFORCEMENT PLATE (AWD) .

  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 Shield

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Disconnect plug connector (1). Release screws (2). Remove cover plate (3). Unscrew holder (4). Tightening torque 23 00 1AZ. See 00 COMPLETE TRANSMISSION .

Fig 2: Identifying Plug Connector, Cover Plate And Screw

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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 00 COMPLETE TRANSMISSION .

Fig 3: Identifying Special Tools (00 9 010)

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Fig 4: Support Transmission With Special Tools (23 4 050), (23 0 132), (00 2 030)

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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 5: Removing Plug From Reversing Light Switch

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Detach plug (1) from reversing light switch. Release cable from retainers.

Fig 6: Release Screws (1) And Remove Holder (2)

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Release screws (1) and remove holder (2).

Fig 7: Identifying Plugs And Servomotor

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Disconnect plugs (1) and (2) from servomotor.

Fig 8: Locating Front Propeller Shaft Screws

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Release screws. Tightening torque 26 11 9AZ. See 11 HOUSING WITH COVER . Remove front propeller shaft at output flange of transfer case and tie to one side. Installation: Replace screws.

Remove propeller shaft from transmission. Release center bearing. Tie propeller shaft to one side. Tasks are described in Removing propeller shaft. See 26 11 000 REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT (CONSTANT-VELOCITY JOINT) .

Fig 9: Locating Transmission Cross-Member Bolts

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Release screws. Remove transmission cross-member. Tighten transmission cross member to rubber mounts 74 N.m. Tighten transmission cross-member to body 19 N.m.

Fig 10: Removing Shift Rod And Lever Out Retainer

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Lift off retainer (1). Disconnect shift rod (2). Installation: Grease shift rod. Make sure shims (3) are in correct position.

Fig 11: Removing Bearing Pin

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

Fig 12: Lifting Out Shift Arm

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Lift out shift arm (1). Installation: Grease bearing pins (1).

Fig 13: Locating Pressure Line Of Clutch Slave Cylinder

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Release nuts and remove clutch slave cylinder. Tightening torque 21 52 5AZ. See 52 CLUTCH OPERATION (HYDRAULIC) .

Fig 14: Transmission Housing Bolts Tightening/Loosening Sequence

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Release screws. Installation: Observe screw fastening sequence without fail. Tightening torque, steel screws 23 00 1AZ. See 00 COMPLETE TRANSMISSION . Aluminum screws/bolts must be replaced. Tightening torque and angle of rotation Aluminum screws/bolts. Torque, 23 00 2AZ. See 00 COMPLETE TRANSMISSION .

Fig 15: Identifying Special Tool (00 9 120) And (00 9 130)

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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/bolts according to angle of rotation. Angle of rotation torque 23 00 2AZ. See 00 COMPLETE TRANSMISSION .

Fig 16: Identifying Sleeves For Correct Seating

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Installation: Check that dowel sleeves are correctly seated. Replace damaged dowel sleeves. Ensure correct position of cover plate

Fig 17: Locating Transmission Input Shaft

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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. See 21 21 500 REMOVING AND INSTALLING/REPLACING CLUTCH (SAC) .

Check clutch plate for friction rust in splines and replace if necessary. See 21 21 500 REMOVING AND INSTALLING/REPLACING CLUTCH (SAC) .

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

Fig 18: Locating Splines Of Input Shaft

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Greasing specification:

• Remove and clean release bearing and release lever. See 21 51 500 REMOVING AND INSTALLING OR REPLACING CLUTCH RELEASE BEARING/LEVER .
• Push on grease scraper ring 21 2 221 as far as it will go.
• Grease splines (1) of input shaft with a brush.
• Detach grease scraper ring.