Supporting transmission

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Support transmission with special tools 23-4050 FIXTURE and 00-2030 DEVICE .

Secure transmission to mounting with tensioning strap (1).

Tasks are described in TRANSMISSION BRACKET .

After completion of work, check transmission oil level. See GEAR OIL LEVEL .

Fig 1: Supporting Transmission Using Special Tools (23 4 050)

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Release bolts (1) and nuts (2) and remove cross-member.

Tightening torque 23 71 2AZ .

Fig 2: Identifying Cross-Member Bolts And Nuts

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Remove complete propeller shaft. See 26 11 000 REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT (CONSTANT-VELOCITY JOINT) .

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 sleeve.

Release nuts and remove clutch slave cylinder.

Tightening torque, see "5AZ" under 21 52 CLUTCH OPERATION (HYDRAULIC) .

Fig 3: Locating Clutch Slave Cylinder Nuts

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Lift off retainer (1).

Clamp off shift rod (2).

Installation:

Grease shift rod.

Grease, refer to CLUTCH COMPONENT GREASE .

Make sure shims (3) are in correct position.

Fig 4: Disconnecting Shift Rod

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

Lift out shift arm.

Installation:

Grease bearing pins (1).

Grease, refer to GEAR SHIFT MECHANISM - OPERATING FLUIDS .

Fig 5: Removing Bearing Pins

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Unlock plug (1) of zero-gear sensor (ON TRANSMISSION) and disconnect.

Fig 6: Identifying Zero-Gear Sensor Lock Plug

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Release remaining eight bolts (1/2).

IMPORTANT: Bolts (2) are longer than bolts (1)

Tightening torque 23 00 1AZ .

NOTE: Bolt (3) must not be released.
Bolt (3) serves to secure the starter motor.

Fig 7: Identifying Starter Motor Bolts

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IMPORTANT: Do not suspend the transmission from the transmission input shaft during removal and installation as this will deform the clutch plate. Pull out transmission towards rear and remove.

Installation:

Check that fitting sleeves (1) are correctly seated.

Replace damaged fitting sleeves.

NOTE: When removing and installing the transmission, without fail use transmission bracket 23-4050 FIXTURE and a jack to support the engine.
Failure to comply with this instruction may result in preliminary damage to the clutch and splined shaft.

Fig 8: Identifying Fitting Sleeves

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Installation:

Check lubrication of transmission input shaft for sticky consistency. If grease is sticky, clean input shaft and replace clutch plate. See 21 21 500 REMOVING AND INSTALLING/REPLACING CLUTCH (GS6-53BZ) S85 USA ONLY .

Check clutch plate for friction rust in splines and replace if necessary. See 21 21 500 REMOVING AND INSTALLING/REPLACING CLUTCH (GS6-53BZ) S85 USA ONLY .

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

Fig 9: Locating Transmission Input Shaft Lubrication

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Installation:

Greasing specification:

Remove and clean release bearing and release lever. See 21 51 500 REMOVING AND INSTALLING OR REPLACING CLUTCH RELEASE BEARING/LEVER .
Push on grease scraper ring as far as it will go. Use 21-2240 RING .
Grease splines (1) of input shaft with a brush. See CLUTCH COMPONENT GREASE .
Detach grease scraper ring.

Fig 10: Locating Grease Scraper Ring And Splines

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