23 00 027 Removing and installing transmission (GS6-53BG/DG)

WARNING: This page is about a different variant/trim than selected.

Special tools required:

00 2 030 .
23 4 150 .

Necessary preliminary tasks:

Disconnect BATTERY .
Drain off TRANSMISSION OIL .
Secure engine in INSTALLATION POSITION .
Remove TRANSMISSION SUPPORT BRACKET .
Remove TRANSMISSION MOUNT .
Remove FRONT AXLE SUPPORT .
No wheel alignment is required for removal and installation of front axle support.
Remove LEFT OUTPUT SHAFT .
Remove RIGHT OUTPUT SHAFT .

After completing work, top up TRANSMISSION OIL . Use only the APPROVED TRANSMISSION OIL .

Release clips on stop/holder (1).

Detach selector lever cable (2) from ball joint.

Release screw (3) and remove bracket.

Fig 1: Identifying Holder And Selector Lever Cable

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Disconnect plug (1) for reversing light switch.

Fig 2: Identifying Plug

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If necessary, disconnect plug connection (1) on zero gear sensor.

Detach cable (2) with holder from transmission.

Fig 3: Identifying Plug Connection And Cable

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NOTE: Pressure line of clutch slave cylinder remains connected.

IMPORTANT: Slowly relieve tension on clutch slave cylinder otherwise air may be drawn in through sealing sleeve.
If possible, do not deflect push rod of clutch slave cylinder.
A deflection of the push rod caused by removal will cause easy escape of fluid. This escape of fluid does not mean that the clutch slave cylinder is damaged.
Replacement is therefore not necessary!

Fig 4: Identifying Clutch Slave Cylinder Nuts

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Release nuts (1) and remove clutch slave cylinder.

Tightening torque 21 52 2AZ .

Release screws (1).

Release holder (2) from engine.

Fig 5: Identifying Holder (2)

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NOTE: Not on diesel engine (W16)

Only on diesel engine (W16)

Slacken nut (1).

Release holder (2) from engine.

Fig 6: Releasing Holder (2) From Engine

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Only on diesel engine (W16)

Remove stud bolts (1) on transmission side for securing catalytic converter.

Fig 7: Identifying Stud Bolts On Transmission Side For Securing Catalytic Converter

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Only on diesel engine (W16)

Undo screw (1) and remove cover cap (2).

Fig 8: Identifying Screw (1) And Cover Cap (2)

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Release starter bolt (1) WAF 13 from above.

Release bolts (2) and remove starter.

Tightening torque. 12 41 4AZ .

Fig 9: Identifying Starter Bolts

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Supporting transmission:

Support transmission with special tools 23 4 150 and 00 2 030

Support transmission from underneath.

Secure transmission with tensioning strap (3).

Tasks are described in Transmission bracket.

After completion of work, check transmission OIL LEVEL .

Fig 10: Supporting Transmission With Special Tools 23 4 150 And 00 2 030

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NOTE: There is no bolt fitted at the lowermost point (1) of the transmission.

Release screws.

Tightening torque 23 00 1AZ.

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

Fig 11: Locating Transmission Bolts

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Installation note:

Check that adapter sleeves (1/2) are correctly seated.

Replace damaged dowel sleeves.

Fig 12: Identifying Adapter Sleeves

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Installation note:

Check lubrication of transmission input shaft for sticky consistency. If grease is sticky, clean drive shaft.

Check clutch plate for friction rust in splines and REPLACE if necessary.

Mechanically remove existing grease and lining abrasion from splines of clutch plate (with a cloth).

Fig 13: Checking Lubrication At Input Shaft

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Installation note:

If reusing the clutch:
Mechanically remove existing grease and lining abrasion from gearings of clutch disc (with a cloth).

Clean clutch hub and regrease.

In new clutch discs the gearing is already greased.

Refer to OPERATING FLUIDS
Remove and clean RELEASE BEARING AND RELEASE LEVER
Add TRANSMISSION OIL .