23 00 028 Removing and installing transmission (GS6-17BG) all-wheel vehicle drive

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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 the thread is corroded, the rust must be removed and it 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 . See DRAINING/TOPPING UP TRANSMISSION OIL IN MANUAL TRANSMISSION or DRAINING/TOPPING UP TRANSMISSION OIL IN MANUAL GEARBOX .
Use only the approved transmission oil.
Failure to comply with this requirement will result in serious damage to the manual gearbox.

Necessary preliminary tasks:

Remove TRANSFER BOX .
Support engine with lifter when removing transmission.

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 and remove clutch slave cylinder.

Tightening torque 21 52 1AZ .

Fig 1: Locating Clutch Slave Cylinder Nuts

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Detach connector (1) from reversing light switch.

Release cable from brackets.

Fig 2: Identifying Reversing Light Switch Connector

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Disconnect connector (1).

Release cable from brackets (2).

Unscrew screws (3) and nuts (4).

Tightening torque 18 20 1/2AZ .

Remove retaining plates (5).

Fig 3: Identifying Connector, Brackets, Screws, Nuts And Retaining Plates

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Release screws (1).

Tightening torque 23 00 1AZ .

Graphic similar

Fig 4: Identifying 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 5: Supporting Transmission With Special Tools (23 4 050)

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Lift off retainer (1).

Detach gearshift rod (2).

Installation note:

Grease gearshift rod.

Grease,

Refer to MANUAL TRANSMISSION -- OPERATING FLUIDS .

Make sure shims (3) are in correct position.

Fig 6: Detaching Gearshift Rod

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

Fig 7: Removing Bearing Journal

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Lift out gearshift arm (1).

Installation note:

Grease bearing journals (1).

Grease,

Refer to MANUAL TRANSMISSION -- OPERATING FLUIDS .

Fig 8: Lifting Gearshift Arm

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With automatic Start/Stop function: Release connector (1) of zero-gear sensor (on transmission).

Fig 9: Identifying Zero-Gear Sensor Connector

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Release screws.

Tightening torque 23 00 1AZ .

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.

NOTE: When removing and installing the transmission, support the front end of the engine at the housing with an installation aid (e.g. gearbox jack).

Fig 10: Locating Screws

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Installation note:

Check that fitting sleeves are correctly fitted.

Replace damaged fitting sleeves.

Ensure correct position of cover plate.

Fig 11: Locating 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 . See REMOVING AND INSTALLING OR REPLACING CLUTCH or REMOVING AND INSTALLING OR REPLACING CLUTCH .

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

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

Fig 12: 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 until limit position.
Grease gearing (1) of input shaft. Refer to MANUAL TRANSMISSION -- OPERATING FLUIDS .
Detach grease scraper ring.

Fig 13: Locating Input Shaft Gearing
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