23 00 018 Removing and installing transmission (GS6-53BZ) (S63)

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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 ENGINE ACOUSTIC COVER .
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 COMPLETE EXHAUST SYSTEM .
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).

Tightening torque 13 62 4AZ .

Remove sensor (3).

Fig 1: Identifying Plug Connection, Screw And Sensor

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Release sheet metal nuts (1).

Remove heat shield (2) on left and right of transmission.

Fig 2: Identifying Heat Shield And Nuts

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Disconnect plug connection (1) from oil pump.

Fig 3: Identifying Plug Connection

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Disconnect plug connection (1) from reversing light switch.

Release cable from brackets.

Fig 4: 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 5: 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 6: Identifying Screws With Brackets Of Hydraulic Lines

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Disconnect plug connection (1).

Fig 7: 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.

Fig 8: Locating Pressure Line Of Clutch Slave Cylinder

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Tightening torque 21 52 1AZ .

Release screws (1).

Tightening torque 23 00 1AZ .

Fig 9: Identifying Transmission 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).

Tasks are described in TRANSMISSION BRACKET .

Fig 10: Supporting Transmission Using Special Tools

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Slacken nut (1).

Release grounding cable (2).

Release screws (3).

Tightening torque 22 32 3AZ .

Fig 11: Identifying Grounding Cable, Nut And Screws

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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 12: 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 13: Removing Bearing Journal

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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 14: Identifying Transmission Bolts

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Disconnect plug connection (1) of zero gear sensor (on transmission).

Fig 15: Identifying Plug Connection Of Zero Gear Sensor (On Transmission)

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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 16: 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 frictional corrosion in taper spline and REPLACE IF NECESSARY .

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

Fig 17: 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 18: Greasing Input Shaft Gearing
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