23 00 028 Removing and installing transmission (GS6-45BZ) N55

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

Necessary preliminary tasks :

Remove underbody protection at front and rear. See REMOVING FRONT UNDERBODY PROTECTION and REMOVING REAR UNDERBODY PROTECTION .
Remove complete EXHAUST SYSTEM .
Remove heat shields.
Partially remove PROPELLER SHAFT .
- Disconnect propeller shaft at transmission.
- Release center mount.
- Tie up 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 lifter when removing transmission.

Unscrew nuts (1).

Release holder (2) and ground strap (3) from vehicle underbody.

Nut (ground strap on body) tightening torque 23 11 8AZ .

Fig 1: Identifying Nuts, Holder And Ground Strap

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Release screws (1).

Remove strut (2).

Similar to graphic.

Fig 2: Identifying Strut Screws
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Release bolts (1) on transmission.

Tightening torque 23 00 1AZ .

Unscrew nuts (2).

Tightening torque 18 20 1AZ .

Bracket remove.

Installation note :

Replace bolts (1).

Fig 3: Identifying Bolts And Nuts

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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 .

Fig 4: Supporting Transmission Using Special Tools (23 4 050/00 2 030)

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Release screws (1).

Tightening torque 18 31 6AZ .

Detach rubber mount of exhaust system.

Fig 5: Identifying Exhaust System Rubber Mount Screws

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Release nuts (1) and screws (2).

Remove gearbox cross member (3).

Tightening torque 22 32 3/4AZ .

Illustration: Automatic

Fig 6: Identifying Transmission Cross Member, Nuts And Screws

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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 and remove clutch slave cylinder.

Tightening torque 21 52 1AZ .

Fig 7: Locating Clutch Slave Cylinder Nuts

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Lift off retainer (2).

Detach gearshift rod (1).

Installation note :

Grease gearshift rod.

Grease: refer to OPERATING FLUIDS .

Fig 8: Detaching Gearshift Rod

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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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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 10: Unlocking Bearing Journal

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Disconnect plug connection (1) on reverse gear switch.

Release line from holder.

Similar to graphic.

Fig 11: Identifying Reverse Gear Switch Plug Connection
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Disconnect plug connection (1) on zero gear sensor.

Release all lines from holder.

Fig 12: Identifying Plug Connection On Zero Gear Sensor

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Release screws.

Tightening torque 23 00 1AZ .

Installation note :

Replace screws.

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 13: Transmission Housing Bolts Tightening/Loosening Sequence

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Installation note :

Check that fitting sleeves are correctly fitted.

Replace damaged fitting sleeves.

Fig 14: 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 frictional corrosion in gearing and replace IF NECESSARY .

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

Fig 15: 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.
Grease: refer to OPERATING FLUIDS .
Detach grease scraper ring.

Fig 16: Locating Input Shaft And Grease Scraper Ring
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