23 00 017 Removing and installing transmission (GS6-17BG) N20

Special tools required:

00 2 030
00 9 120
00 9 130
21 2 220
23 4 050

IMPORTANT: To prevent severe damage to the engine block, the protruding threads of the transmission bolts must be strictly checked for corrosion and damage before removal .
If there are signs of corrosion, the rust must be removed and the threads must be cleaned before removal .
Replace rusted, damaged bolts.

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

IMPORTANT: After completion of work, check transmission fluid level.
Use only the approved transmission oil.
Failure to comply with this requirement will result in serious damage to the manual gearbox.

Necessary preliminary tasks:

CLAMP OFF BATTERY
Remove underbody protection . See REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION or REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION at front and rear
Remove complete EXHAUST SYSTEM
Partially remove propeller shaft . See COMPLETELY REMOVING AND INSTALLING PROPELLER SHAFT (INSERTED - REAR FLEXIBLE DISC) (WITHOUT VIBRATION ABSORBER) or REMOVING AND REFITTING COMPLETE PROPELLER SHAFT (PUSH-FIT - FLEXIBLE JOINT AT REAR) (WITH VIBRATION ABSORBER) .
- Disconnect propeller shaft at transmission.
- Release center mount.
- Tie back propeller shaft to underbody
  NOTE: Bending the propeller shaft by an excessive angle can cause premature damage to the joint/propeller shaft!
Support engine with jack when removing gearbox

Release screws (1).

Tightening torque 23 00 1AZ . See TRANSMISSION IN GENERAL or TRANSMISSION IN GENERAL .

Fig 1: Identifying Screws

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Release nuts (1).

Tightening torque 18 20 1AZ .

Unfasten screws (2).

Tightening torque 18 20 2AZ .

Remove bracket (3).

Slacken nut (4).

Tightening torque 23 11 8AZ .

Release ground strap from transmission.

Fig 2: Identifying Nuts, Screws And Bracket

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Unscrew holder (1).

Fig 3: Identifying Holder

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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.

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

Tightening torque 21 52 1AZ .

Fig 4: Locating Clutch Slave Cylinder Nuts

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Detach connector (1) from reverse gear switch.

Detach cables from brackets on transmission.

Fig 5: Locating Brackets Cables On Transmission

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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 GEARBOX HOLDER .

After completion of work, check transmission fluid level.

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

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Release screws (1).

Tightening torque 22 32 3AZ .

Fig 7: Identifying Screws

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Detach retaining clip.

Fig 8: Detaching Retaining Clip

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IMPORTANT: Retaining clip must interlock captively with retaining web (1) behind gearshift rod pin.

Fig 9: Identifying Retaining Web

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Pull gearshift rod (1) out of gearshift rod joint (2).

Installation note:

Grease gearshift rod pin (3).

Grease,

Refer to MANUAL TRANSMISSION -- OPERATING FLUIDS .

Fig 10: Pulling Gearshift Rod

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

Fig 11: Unlock Bearing Journal

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Lift out gearshift arm (1).

Installation note:

Grease bearing journal.

Grease,

Refer to MANUAL TRANSMISSION -- OPERATING FLUIDS .

Fig 12: Lifting Gearshift Arm

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Release screws.

Installation note:

Tightening torque, steel screws 23 00 1AZ . See TRANSMISSION IN GENERAL or TRANSMISSION IN GENERAL .

IMPORTANT: Do not allow transmission to hang on transmission input shaft when removing and installing, as the clutch disc will be deformed. Pull out transmission towards rear and remove.

Fig 13: Locating Screws

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Installation note:

Check fitting sleeves (1 and 2) for correct fit.

Replace damaged sleeves.

Ensure correct position of cover plate.

Fig 14: Locating Fitting Sleeves

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Installation note:

Check lubrication of transmission input shaft for sticky consistency. If grease is sticky, clean drive shaft and replace clutch disc . See REMOVING AND INSTALLING OR REPLACING CLUTCH or REMOVING AND INSTALLING OR REPLACING CLUTCH .

Check clutch disc for friction rust in gearing and replace if necessary . See REMOVING AND INSTALLING OR REPLACING CLUTCH or REMOVING AND INSTALLING OR REPLACING CLUTCH .

Remove any grease and lining abrasion from gearing of clutch disc by mechanical means (with a cloth).

Fig 15: Locating Transmission Input Shaft

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Installation note:

Greasing specification:

Remove and clean release bearing and release lever (do not grease).
Push on grease scraper ring 21 2 220 until limit position.
Grease gearing (1) of input shaft with a brush.
Refer to MANUAL TRANSMISSION -- OPERATING FLUIDS .
Detach grease scraper ring.

Fig 16: Locating Gearing Of Input Shaft
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