Installing the manual transmission (GS6L55TZ)

Prepare for the installation of the manual transmission 

• Check the lubrication of the transmission input shaft for sticky consistency and clean the transmission input shaft as needed.
• Check whether the clutch disc is free of grease, replace the clutch disc if necessary.
• Remove any grease and lining abrasion from gearing (arrows) of the clutch disc by mechanical means (with a cloth).

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• Remove and clean the release bearing and release lever (do not grease).
• Push the grease scraper ring on 0 494 650 (21 2 240) till reaching the stop  .
• Grease the gearing (1) of the input shaft with a brush.

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• Detach grease scraper ring.
• Install the release lever and release bearing.

• Transmission flange-mount.
• Fit the transmission bolts (arrows) and apply hand-tight.

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• Connect the connector (1) to the transmission.

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• Insert and install the holder (4).
• Position screws (1) and tighten them slightly.
• Replace the screw (2).

  Parts:  Screw

• Tighten down screw (2).

Catalytic converter to holder
M8 Replace screw.	Tightening torque	19 Nm

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• Tighten nut (3).

Catalytic converter to holder
M8	24 Nm

• Install holder (1).

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• Install the ground strap.
• Tighten down screw (1).

Ground strap to transmission or body
M8	tightening torque	19 Nm

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• Grease the gearshift rod pin (1) of gearshift rod (2).

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• Hook the gearshift rod (1) in arrow direction into the gearshift lever (3).
• Insert retaining clip (2).

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• Install the bearing journal (1) in arrow direction.
• Lock the fuses (2) in arrow direction.

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• Hook the gearshift rod (1) in arrow direction into the gearshift rod joint (3).
• Insert retaining clip (2).

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• Replace screws (1).

  Parts:  Screws

• Install the clutch slave cylinder (2) with the holder (3).
• Insert screws (1) and tighten.

Clutch slave cylinder to clutch housing/transmission housing
M8 x 25 Replace screws.	19 Nm

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• Tighten the transmission bolts in the sequence (1) to (9).

Transmission to engine
M8	Tightening torque	19 Nm
M12	Tightening torque	66 Nm

Follow-up work 

• Refer to FASTENING THE PROP SHAFT (PARTIALLY REMOVED) .
• Refer to INSTALLING FRONT HEAT SHIELD .
• Refer to INSTALLING THE REAR HEAT SHIELD .
• Refer to INSTALLING THE LEFT THRUST FIELD .
• Refer to INSTALLING TANK COVER .
• Refer to INSTALLING TRANSMISSION CROSS MEMBER .
• Refer to INSTALLING THE INTERMEDIATE PIPE .
• Refer to INSTALLING EXHAUST SYSTEM .
• Refer to INSTALLING THE CONNECTING SUPPORTS ON THE TUNNEL .
• Refer to INSTALLING THE OXYGEN SENSOR MONITOR FOR CYLINDERS 4 TO 6 .
• Refer to PARTIALLY INSTALLING THE COOLANT EXPANSION TANK OF THE HIGH-TEMPERATURE COOLANT CIRCUIT .
• Refer to INSTALLING THE RIGHT INTAKE FILTER HOUSING (FRONT-END STRUT REMOVED) .
• Refer to CHECKING/ADDING TO THE OIL LEVEL IN THE MANUAL TRANSMISSION (GS6L55TZ) .
• Refer to INSTALLING THE STIFFENING PLATE .
• Refer to INSTALLING THE LEFT AND RIGHT FRONT UNDERSHIELD .
• Refer to INSTALLING FRONT UNDERBODY PROTECTION .
• Refer to INSTALLING THE FRONT SPOILER .
• Refer to INSTALLING THE FRONT-END STRUT .
• Refer to INSTALLING ACOUSTIC COVER .
• Refer to INSTALLING THE STRUT BRACE .
• Refer to TAKING HOOD OUT OF THE SERVICE POSITION .