23 00 018 Removing and installing transmission (GS6-53BZ) (N63)

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Special tools required:

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

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

IMPORTANT: After completing work:

Check TRANSMISSION OIL LEVEL .
Use only the approved transmission oil. Refer to OPERATING FLUIDS .

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

Necessary preliminary tasks:

CLAMP OFF BATTERY
Remove both suspension cross-braces . See 51 71 345 REMOVING AND INSTALLING/REPLACING LEFT (REAR) SUSPENSION CROSS-BRACE or 51 71 346 REMOVING AND INSTALLING/REPLACING RIGHT (REAR) SUSPENSION CROSS-BRACE
Remove BOTH INTAKE SILENCER HOUSINGS
Remove underbody protection . See 51 47 490 REMOVING AND INSTALLING/REPLACING UNDERBODY PROTECTION (FRONT) or 51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION at front and rear
Remove PROPELLER SHAFT
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

Disconnect plug connection (1).

Release screw (2).

Remove sensor (3).

Fig 1: Identifying Plug Connection, Screw And Sensor

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Disconnect plug connection (1) from oil pump.

Fig 2: Identifying Plug Connection

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Disconnect plug connection (1) from reversing light switch.

Release cable from brackets.

Fig 3: Identifying Plug Connection

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Release screw (1).

Loosen the hydraulic lines (2).

Tightening torque 17 22 1AZ

Installation note:

Check installed position of hydraulic lines (2).

Replace sealing rings.

Fig 4: Identifying Hydraulic Lines Installation Position With Screws

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Loosen screws (1) with brackets of hydraulic lines.

Tightening torque 17 22 3AZ .

Release and disconnect hydraulic lines (2) from brackets.

Fig 5: Identifying Screws With Brackets Of Hydraulic Lines

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Disconnect plug connection (1).

Fig 6: Identifying Plug Connection

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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.

Unscrew nuts.

Remove clutch slave cylinder.

Tightening torque 21 52 5AZ.

Fig 7: Locating Pressure Line Of Clutch Slave Cylinder

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Release screws (1).

Tightening torque 23 00 1AZ .

Fig 8: Identifying Transmission Screws

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Release screw (1) on left and right of axle.

Remove cover plate (2) on left and right of axle.

Remove bolt (3) on left and right of axle.

Tightening torque 31 10 1AZ .

Fig 9: Identifying Cover Plate, Bolt And Screws

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Screw on special tool 11 8 910 .

Fig 10: Identifying Special Tool (11 8 910)

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Adjust distance (1) between cross bar and facing using nuts (2).

Nuts (2) must be screwed down in opposite direction after distance has been adjusted.

IMPORTANT: Distance:

N63 38 mm

Fig 11: Identifying Distance Between Cross Bar And Facing

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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 fluid level.

Fig 12: Supporting Transmission Using Special Tools

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Remove TRANSMISSION CROSS MEMBER .

Lever out retainer (1).

Detach gearshift rod (2).

Installation note:

Grease gearshift rod.

Grease, refer to OPERATING FLUIDS .

Make sure shims (3) are in correct position.

Fig 13: Detaching Gearshift 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 OPERATING FLUIDS .

Fig 14: Removing Bearing Journal

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Installation note:

Check installed position of rubber plug (1).

Fig 15: Identifying Rubber Plug Installation Position

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Installation note:

Check installed position of rubber plug (1).

Fig 16: Identifying Rubber Plug Installation Position

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Installation note:

Check installed position of rubber plug (1).

Fig 17: Identifying Rubber Plug Installation Position

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Release screws (1) and (2).

IMPORTANT: Bolts (2) are shorter than bolts (1).

Tightening torque 23 00 1AZ .

IMPORTANT: Do not allow the transmission to hang from the transmission input shaft during removal and installation as this will deform the clutch disc.

Fig 18: Identifying Transmission Bolts

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Installation note:

Pay attention to correction position of fitting sleeves.

Replace damaged fitting sleeves.

Ensure correct position of cover plate.

Fig 19: Identifying Fitting Sleeves Position

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Installation note:

REMOVE CLUTCH OPERATOR AND RELEASE LEVER and clean.

Installation note:

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

Check clutch disc for friction rust in taper splines and REPLACE IF NECESSARY .

Mechanically remove old grease and lining abrasion from the taper splines of the clutch disk (with a cloth).

Fig 20: Inspecting Transmission Input Shaft

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Installation note:

Greasing specification:

Remove 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 OPERATING FLUIDS .
Detach grease scraper ring.

Fig 21: Greasing Input Shaft Gearing
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