Removing and installing transmission (GS6-45BZ): Notes

Special tools required:

23 4 050
00 2 030
21 2 240

Attention!

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.

Attention!

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 work:

Remove underbody protection at front and rear. Refer to REMOVING AND INSTALLING/REPLACING UNDERBODY PROTECTION (FRONT) and REMOVING REFITTING/REPLACING REAR ENGINE UNDERCOVER .
Remove STIFFENING PLATE .
Remove complete EXHAUST SYSTEM .
Remove propeller shaft. Refer to COMPLETELY REMOVE AND INSTALL THE PROPELLER SHAFT MADE OF STEEL (INSERTED AT THE REAR) or REMOVING AND INSTALLING CARBON PROPELLER SHAFT (INSERTED) COMPLETE .
Support engine with jack when removing gearbox

Removal:

Fig 1: Transmission Input Shaft Screws Tightening Sequence

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Remove gasket (1).

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Illustration shows dual-clutch transmission.

Release and unplug connectors (1) from brackets.

Release and disconnect the cable (2) from brackets.

Illustration shows dual-clutch transmission.

Release bolts (1) on transmission.

Remove holder (2).

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Release screws (1) from transmission.

Unscrew nuts (2).

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Illustration shows dual-clutch transmission. Slacken nut (1).

Release ground cable (2) from body.

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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 .

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Illustration shows dual-clutch transmission.

Loosen screws (1).

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NOTE: Pressure line of clutch slave cylinder remains connected.

Attention!

Slowly relieve tension on clutch slave cylinder otherwise air is drawn in through sealing cup.

Release nuts (1) and remove clutch slave cylinder.

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Remove retainer (2).

Detach gearshift rod (1).

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

Lift out gearshift arm.

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Disconnect plug connection (1) of gear sensor.

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Release remaining screws.

Attention!

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

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Installation:

Installation note:

Check that fitting sleeves (1) are correctly seated.

Replace damaged fitting sleeves (1).

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Installation note:

Check lubrication of transmission input shaft for sticky consistency. If the grease is sticky, clean drive shaft and check to make sure the clutch disc is free of grease, REPLACE CLUTCH DISC if necessary.

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).

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Installation note:

Greasing specification:

Remove and clean RELEASE BEARING AND RELEASE LEVER .

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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.
INSTALL THE RELEASE LEVER AND RELEASE BEARING .

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Tighten down nuts (2).

Tighten screws (1) on transmission.

Tightening torque 23 00 1AZ .

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Illustration shows dual-clutch transmission.

Install holder (2).

Tighten screws (1) on transmission.

Tightening torque 23 00 1AZ .

Lightly tighten the remaining screws on the transmission.

Tighten the screws in the specified screwing sequence.

Tightening torque 23 00 1AZ .

Attention!

Do not allow transmission to hang on transmission input shaft when installing, as the clutch disc will be deformed.

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Insert and engage plug connection (1) of gear sensor.

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Insert gearshift arm from top.

Install bearing journals (1) and lock in direction of arrow.

Installation note:

Grease bearing journals (1).

Grease: refer to OPERATING FLUIDS .

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Attention!

The retaining clip must interlock captively with the retaining web (1) behind the gearshift rod pin.

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Attach gearshift rod (1).

Insert fuse (2).

Installation note:

Grease gearshift rod.

Grease: refer to OPERATING FLUIDS .

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Install the clutch slave cylinder and tighten nuts (1).

Part : Replace nuts.

Tightening torque 21 52 1AZ .

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Illustration shows dual-clutch transmission.

Tighten down screws (1).

Tightening torque 22 32 3AZ .

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Remove transmission jack.

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Illustration shows dual-clutch transmission.

Attach ground cable (2) to body.

Tighten nut (1).

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Illustration shows dual-clutch transmission.

Install the cable (2) in the bracket.

Lock the connector (1) and install in brackets.

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Install gasket (1).

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Required re-working:

Support engine with jack when installing transmission
Install propeller shaft. Refer to COMPLETELY REMOVE AND INSTALL THE PROPELLER SHAFT MADE OF STEEL (INSERTED AT THE REAR) or REMOVING AND INSTALLING CARBON PROPELLER SHAFT (INSERTED) COMPLETE .
Install complete EXHAUST SYSTEM .
Install STIFFENING PLATE .
Install underbody protection at front and rear. Refer to REMOVING AND INSTALLING/REPLACING UNDERBODY PROTECTION (FRONT) and REMOVING REFITTING/REPLACING REAR ENGINE UNDERCOVER .