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

IMPORTANT: After completion of work, check TRANSMISSION OIL LEVEL .

Use only approved MANUAL TRANSMISSION - OPERATING FLUID .

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

IMPORTANT: Aluminum screws/bolts must be replaced each time they are released.

Aluminum screws/bolts are permitted with and without color coding (blue).

For reliable identification:

Aluminum screws/bolts are not magnetic.

Jointing torque and angle of rotation must be observed without fail (risk of damage).

Necessary preliminary work

Clamp off battery. See 61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD
Remove front UNDERBODY PROTECTION
Remove rear UNDERBODY PROTECTION .
Remove complete EXHAUST SYSTEM
Remove heat shields
Support engine with jack when removing gearbox

Remove holder (1).

Fig 1: Identifying Holder

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Release screws (1).

Disconnect connector (2).

Steel screws, tightening torque 23 00 1AZ .

Aluminum screws, tightening torque 23 00 2AZ .

Release aluminum screws with special tool 00 9 010 .

Fig 2: Identifying Connector

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Release screws (1).

Remove holder (2).

Fig 3: Identifying Holder Screws

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Unlock connector (1) from reversing light switch and detach.

Release cable from brackets.

Fig 4: Identifying Plug Connection

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Release screws (1).

Remove exhaust bracket (2).

Tightening torque 23 71 4AZ .

NOTE: Graphic similar

Fig 5: Identifying Exhaust System Bracket With Mounting Screws

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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).

After completion of work, check transmission oil level.

Fig 6: Supporting Transmission Using Special Tools (23 4 050)

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Release bolts (1) and nuts (2) and remove cross-member.

Tightening torque 23 71 2AZ .

Fig 7: Identifying Cross-Member Bolts And Nuts

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Remove propeller shaft from transmission. See 26 11 000 REMOVING AND INSTALLING PROPELLER SHAFT (INSERTED) COMPLETELY .

IMPORTANT: Do not allow propeller shaft to hang from fixed ball joint (risk of damage).

NOTE: Pressure line of clutch slave cylinder remains connected.

IMPORTANT: Relieve tension on clutch slave cylinder slowly; otherwise air will be drawn in through sealing cup.

Fig 8: Locating Clutch Slave Cylinder Nuts

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Release nuts and remove clutch slave cylinder.

Tightening torque 21 52 5AZ .

Lever out retainer (1).

Disengage gearshift rod (2).

Installation note:

Grease gearshift 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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Unlock bearing journal (1) in direction of arrow and remove.

Lift out gearshift arm.

Installation note:

Grease bearing journals (1).

Grease, refer to MANUAL TRANSMISSION - OPERATING FLUIDS .

Fig 10: Removing Bearing Pin

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Release screws.

Steel screws, tightening torque 23 00 1AZ .

Aluminum screws/bolts (3, 4, 5, 9, 10), tightening torque 23 00 2AZ .

IMPORTANT: Do not suspend the transmission from the transmission input shaft during removal and installation as this will deform the clutch disc. Pull out transmission towards rear and remove.

Fig 11: Transmission Housing Bolts Tightening/Loosening Sequence

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Installation note:

Tighten down screws/bolts to specified torque.

Special angle-of-rotation tool 00 9 120 with magnet 00 9 130 .

Secure to vehicle underbody and screw down aluminum screws/bolts in accordance with angle of rotation.

Angle of rotation 23 00 2AZ .

Fig 12: Securing Angle Of Rotation Using Special Tool (00 9 120) And Magnet (00 9 130)

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Installation note:

Check that fitting sleeves are correctly fitted.

Replace damaged fitting sleeves.

Ensure correct position of cover plate.

Fig 13: Identifying Fitting Sleeves

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Installation note:

Check lubrication of transmission input shaft for sticky consistency. If grease is sticky, clean transmission input shaft and REPLACE CLUTCH DISC .

Check clutch disc for friction rust in gearing and REPLACE if necessary.

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

Fig 14: Locating Transmission Input Shaft

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Installation note:

Greasing specification:

Remove and clean RELEASE BEARING AND RELEASE LEVER .
Push on grease scraper ring 21 2 240 to the limit position.
Grease gearing (1) of input shaft with a brush. refer to MANUAL TRANSMISSION - OPERATING FLUIDS .
Detach grease scraper ring.

Fig 15: Identifying Grease Scraper Ring (21 2 240) And Splines

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