Removal & Installation

Disconnect battery, battery positive lead from battery terminal. See INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .

Remove intake air manifold.

Remove heater bulkhead. See REMOVING AND INSTALLING/REPLACING HEATER BULKHEAD .

Remove fan with fan impeller. See COOLING FANS .

Remove engine splash guard.

Release screws (1). Release screws (2) and remove reinforcement plate (3). See Fig 1 . Upon installation, replace screws (2). Install all screws. Tighten screws (2) to torque and then to angle of rotation. See TORQUE SPECIFICATIONS  . Tighten down screws (1).

Fig 1: Removing Reinforcement Plate

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Remove exhaust catalytic converter and intermediate pipes. See REPLACING INTERMEDIATE PIPES (S54) and REMOVING AND INSTALLING/REPLACING CATALYTIC CONVERTER (S54) .

Remove heat shield (1). See Fig 2 .

Fig 2: Removing First Heat Shield

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Remove heat shield (1). See Fig 3 . Remove holder for engine underbody protection at rear.

Fig 3: Removing Second Heat Shield

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Disconnect plug for transmission oil temperature sensor (1) and transmission speed sensor (2). See Fig 4 .

Fig 4: Disconnecting Plugs For Temperature Sensor & Speed Sensor

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Disconnect plug for reversing light switch (1). See Fig 5 .

Fig 5: Locating Plug For Reversing Light Switch

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Unclip hydraulic lines at holders (1). See Fig 6 . Upon installation, replace holder (1).

Fig 6: Unclipping Hydraulic Lines

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Unclip hydraulic lines at holders (2). See Fig 7 . Pressure pipe remains connected. NOTE: Slowly relieve tension on clutch slave cylinder (3) when removing otherwise air will be drawn in through sealing sleeve. Release nuts and remove clutch slave cylinder (3). Upon installation, replace holder (2). Tighten fasteners to specification. See TORQUE SPECIFICATIONS  .

Fig 7: Removing Clutch Slave Cylinder

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Support transmission with Special Tools (00 2 030, 23 0 041) and (23 0 042). See Fig 8 .

Fig 8: Supporting Transmission

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Release screws and remove cross-member (1). See Fig 9 . Lower transmission until cylinder head touches firewall. Support engine at front. Upon installation, pay attention to position of vibration damper (2). Tighten fasteners to specification. See TORQUE SPECIFICATIONS  .

Fig 9: Removing Cross Member

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Unfasten screws. See Fig 10 . Upon installation, replace self-locking nuts. Tighten mounting screws of flexible disk on transmission flange by means of nuts only. Tighten fasteners to specification. See TORQUE SPECIFICATIONS  .

Fig 10: Locating Mounting Screws Of Flexible Disk

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Grip propeller shaft and release nuts. See Fig 11 . Bend propeller shaft downwards at center bearing (1). Detach propeller shaft from transmission output flange and tie back to side on vehicle underbody. Upon installation, Tighten fasteners to specification. See TORQUE SPECIFICATIONS  .

Fig 11: Detaching Propeller Shaft From Transmission Output Flange

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Lever out retaining ring (1) with a screwdriver. See Fig 12 . Push retaining ring (1) forwards slightly.

Fig 12: Levering Out Retaining Ring

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Drive out retaining pin (1) on selector rod linkage with Special Tool (23 0 240). See Fig 13 . To remove retaining pin (1), slide selector rod into transmission.

Fig 13: Locating Retaining Pin

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Release screws on actuator. See Fig 14 . Upon installation, Tighten fasteners to specification. See TORQUE SPECIFICATIONS  .

Fig 14: Releasing Screws On Actuator

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Release screw (1). See Fig 15 . Release screw (2) on actuator. Hydraulic lines and connectors remain connected. Remove actuator. Upon installation, replace screw (1). Tighten fasteners to specification. See TORQUE SPECIFICATIONS  .

Fig 15: Removing Actuator

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Unfasten screws. See Fig 16 . Pull out transmission as far as possible towards rear, turn approx. 10° in counterclockwise direction and remove. Upon installation, Tighten fasteners to specification. See TORQUE SPECIFICATIONS  .

Fig 16: Locating Transmission Mounting Screws

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Installation: pay attention to correction position of dowel sleeves. See Fig 17 . Replace damaged dowel sleeves. Ensure correct position of cover plate.

Fig 17: Checking Dowel Sleeves

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Installation: remove release unit, release lever and clean.

Installation: check lubrication of transmission input shaft for sticky consistency. See Fig 18 . If grease is sticky, replace clutch plate. Check clutch plate 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 18: Checking Lubrication Of Transmission Input Shaft

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To complete installation, reverse removal procedure.