23 00 028 Removing and installing transmission (GS6-45BZ)

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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 completion of repair 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.

IMPORTANT: For vehicles with N54/N55 engine up to production date 09/2012, aluminum bolts for the for the securing of the transmission are also installed.
As of production date 09/2012, only steel bolts are installed for the securing of the transmission.

NOTE: 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) .
The aluminum bolts can be optionally replaced by steel bolts.

Necessary preliminary tasks:

Remove FRONT UNDERBODY PROTECTION
Remove REAR UNDERBODY PROTECTION
Remove complete EXHAUST SYSTEM
Remove heat shields
Release hose sockets from charge air cooler on left and right
Support engine with jack when removing gearbox

Remove upper part of cable duct (1).

Fig 1: Identifying Upper Cable Duct

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Remove holder (1-3).

Fig 2: Identifying Transmission Holders

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Release screws (1).

Disconnect connector (2).

Steel screws, tightening torque 23 00 1AZ .

Aluminum screws, tightening torque 23 00 1AZ .

Release aluminum screws with special tool 00 9 010.

Fig 3: Identifying Connector And Screws

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Disconnect plug connection (1) on reverse gear switch.

Remove reverse gear switch.

Tightening torque 23 14 1AZ .

Fig 4: Identifying Plug Connection On Reverse Gear Switch

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Release nuts (1) and (2).

Tightening torque 18 20 1AZ .

Fig 5: Identifying Nuts

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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 6: Identifying Cover Plate, Bolt And Screws

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Screw on special tool 11 8 910 .

Fig 7: 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:

N55 38.5 mm

Fig 8: 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 GEARBOX HOLDER .

After completion of work, check transmission fluid level.

Fig 9: Supporting Transmission Using Special Tools

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Slacken nut (1).

Unfasten ground strap (2).

Fig 10: Identifying Ground Strap Nut

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Unscrew nut (1) and bolts (2).

Remove gearbox cross member (3).

Tightening torque 22 32 3/4AZ .

Graphic shows: Automatic

Fig 11: Identifying Gearbox Cross Member, Nut And Bolts

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REMOVE propeller shaft from transmission.
Release center mount.
Note :
Bending the propeller shaft by an excessive angle can cause premature damage to the joint/propeller shaft!
Tie up propeller shaft to underbody.

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 12: Locating Pressure Line Of Clutch Slave Cylinder

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Release nuts and remove clutch slave cylinder.

Tightening torque 21 52 1AZ .

Lift off retainer (2).

Detach gearshift rod (1).

Installation note:

Grease gearshift rod.

Grease, refer to OPERATING FLUIDS .

Fig 13: Detaching Gearshift Rod

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

Fig 14: Identifying Retaining Web

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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 15: Removing Bearing Journal

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Release screws.

In vehicles with an N54/N55 engine from production date 09/2012, only steel bolts are installed.

Steel screws, tightening torque 23 00 1AZ .

Aluminum screws (3, 4, 5, 9, 10), tightening torque 23 00 1AZ .

Release aluminum screws with special tool 00 9 010.

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

Fig 16: 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 1AZ .

Fig 17: Tightening Down Screws/Bolts Using Special Tool

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Installation note:

Check that fitting sleeves are correctly fitted.

Replace damaged fitting sleeves.

Fig 18: Identifying Fitting Sleeves

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Installation note:

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

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

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

Fig 19: Inspecting 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 OPERATING FLUIDS .
Detach grease scraper ring.

Fig 20: Greasing Input Shaft Gearing
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