31 10 001 Completely removing and installing the front axle with engine and transmission (S63T0, manual gearbox)

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Special tools required:

13 5 162

IMPORTANT: Removal weight approximately 250 kg to 450 kg.
Check vehicle payload.
If necessary, load front footwell with approx. 200 kg.
Note safety information of TABLE LIFT !

Necessary preliminary tasks:

Position vehicle on vehicle hoist so its weight is centered.
Clamp off BATTERY .
Move engine compartment lid into service position.
SUCTION OFF air conditioning.
Remove both INTAKE SILENCER HOUSINGS .
REMOVE fan cowl with electric fan.
Remove complete PROPELLER SHAFT .
Remove left and right BRAKE CALIPER and place to one side.
Remove rear right SUSPENSION CROSS-BRACE
Remove AUXILIARY WATER PUMP .
Remove left and right WHEEL ARCH COVER (FRONT SECTION) .
Remove left and right COVER FOR STEERING ASSEMBLIES .
Remove left and right auxiliary radiator . See 17 11 016 REMOVING AND INSTALLING/REPLACING RIGHT AUXILIARY COOLANT COOLER (S63 B44 T 0) or 17 11 017 REMOVING AND INSTALLING/REPLACING LEFT AUXILIARY COOLANT COOLER (S63 B44 T 0) .
Release coolant hoses from radiator.

Release wiring harness from supplementary electronics box (1) and secure on the engine against falling.

Fig 1: Identifying Supplementary Electronics Box

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Unlock and detach vacuum line (1) from vacuum pump.

Fig 2: Identifying Vacuum Line From Vacuum Pump

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Release screws (1).

Pull off A/C line (3) from A/C line (2).

Tightening torque: 64 53 7AZ .

Fig 3: Identifying A/C Lines And Screw

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Release screw (1).

Pull off A/C line (2) and place to one side.

Tightening torque: 64 53 3AZ .

Installation note:

Replace sealing rings and moisten with refrigerant oil.

Fig 4: Identifying Refrigerant Lines And Screws

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Release screw (1).

Release auxiliary water pump (2) together with bracket in upward direction from holder.

Fix auxiliary water pump (2) to engine with suitable auxiliary materials.

Fig 5: Identifying Auxiliary Water Pump And Screw

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Recycling:

Catch and dispose of escaping fuel with auxiliary materials.

Observe country-specific waste disposal regulations.

Unlock and disconnect fuel delivery line (1), seal off with special tool 13 5 160.

Seal off fuel delivery line (2) with special tool 13 5 162 .

Fig 6: Sealing Off Fuel Lines Using Special Tools

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Release screw (1) from vehicle underbody direction.

Tightening torque 32 31 2AZ .

Installation note:

Replace screw.

Detach steering shaft lower section.

Fig 7: Identifying Screw From Vehicle Underbody

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Recycling

Transmission oil emerges when fluid lines are detached from transmission oil cooler.

Catch and dispose of escaping transmission oil in a suitable container.

Observe country-specific waste disposal regulations.

Unlock transmission fluid lines (1) and detach from gearbox oil cooler.

Press in locks (2), raise transmission oil cooler towards top.

Fig 8: Identifying Transmission Fluid Lines With Locks

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Remove circlips (1).

Unlock lines (2) and (3) and pull off from cooling loop.

IMPORTANT: Catch and dispose of emerging oil.

Installation note:

Reinstall circlips.

Fig 9: Identifying Lines With Circlips

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Release nut and remove screw (3).

Fix brake caliper (1) with a suitable auxiliary materials (2).

Installation note:

Keep wishbone to swivel bearing connection clean and free from oil and grease.

Note direction of insertion of screw.

Screw must rest correctly in groove of ball stud.

Replace self-locking nut.

Tightening torque 31 12 6AZ .

Fig 10: Identifying Brake Caliper, Auxiliary Materials And Screw

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Release screws (1).

Release deformation element (3) from front axle support (2).

Fig 11: Identifying Deformation Element, Front Axle Support And Screws

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Release nut (1) and remove screw.

Release spring strut from wishbone (2).

Installation note:

Replace screw and nut.

Note direction of insertion of screw.

Adhere to the assembly sequence.

Tightening torque 31 12 7AZ .

Fig 12: Identifying Spring Strut, Wishbone And Mounting Nut

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Remove heat shield (1) on left and right of transmission.

Fig 13: Identifying Heat Shield

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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 (2) and remove clutch slave cylinder (1).

Tightening Torque: 21 52 1AZ .

Fig 14: Identifying Clutch Slave Cylinder And Nuts

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Detach retaining clip.

Fig 15: Removing Locking Clip

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IMPORTANT: New retaining clips fitted as from 04.08.
Retaining clip must interlock with retaining web (1) behind gearshift rod pin.

Fig 16: Identifying Retaining Web

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Pull gearshift rod (1) out of gearshift rod joint (2).

Installation note:

Grease gearshift rod pin (3).

Grease,

Refer to OPERATING FLUIDS .

Fig 17: Pulling Shift Rod From Shift Rod Joint

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

Fig 18: Removing Bearing Journal

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Lift out gearshift arm (1).

Installation note:

Grease bearing journal.

Grease,

Refer to OPERATING FLUIDS .

Fig 19: Lifting Out Gearshift Arm

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IMPORTANT: Coordinate determination always begins at the top.

Position engine assembly on table top A .

Position transmission on table top B

Table top B is adjustable in a longitudinal direction (see arrow).

Fig 20: Identifying Working Plates

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Structure of table lift .

Position retaining elements (3) with fixture (60) on table top B for transmission at coordinates 6/3 and 6/6.

Position retaining elements (2) with fixture (80) on table top A for front axle support at coordinates 2/2 and 2/7.

Position retaining elements (1) with fixture (50) on table top A for front axle support at coordinates 7/3 and 7/6.

Position fixture (4) on table top A for swivel bearing at coordinates 4/1 and 5/8.

Fig 21: Identifying Retaining Elements Components

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NOTE: Possible mounting points for front axle support and transmission.
Note position (1 to 3).

Fig 22: Identifying Mounting Points For Front Axle Support And Transmission

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Secure fixture of swivel bearing (1) on brake disc with wheel studs (2).

Secure adjusting screw (3).

Fig 23: Identifying Fixture Of Swivel Bearing, Wheel Studs And Adjusting Screw

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Unfasten screws (2).

Tightening torque 17 22 5AZ .

Carefully place engine oil cooler (3) on table lift.

Fig 24: Identifying Engine Oil Cooler And Screws

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Slacken nut (1).

Release grounding cable (2).

Release screws (3).

Tightening torque 22 32 3AZ .

Fig 25: Identifying Grounding Cable And Screws

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Release screws (1, 2 and 3).

Tightening torque 31 10 1AZ .

Installation note:

Check threads for damage; if necessary, repair with HELICOIL THREAD INSERTS .

Screw M12x1, 5x65.
Screw M12x1, 5x95.
Screw M10x35.

Fig 26: Identifying Front Axle Screws
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Tighten down first screws (1) and then screws (2).

Completely remove front axle with engine and transmission with lift

81 22 2 184 136 carefully downwards.

NOTE: Graphic diagram N63 Hybrid

Fig 27: Removing Front Axle From Engine And Transmission

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Installation note:

Position the table lift beneath the vehicle.

The inclination of the table lift (1) can be adjusted using the adjusting screws (2).

Fig 28: Adjusting Table Lift Inclination

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After installation:

Check and add engine oil.
Fill and bleed hydraulic system.
Check line connections for leak tightness
Check and clear the fault memory
Carry out WHEEL ALIGNMENT PROCEDURE .