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 TRANSMISSION OIL .
Secure engine in INSTALLATION POSITION .
Remove TRANSMISSION SUPPORT BRACKET .
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 .

Release clips on limit position/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.

NOTE: Not on diesel engine

Fig 5: Identifying Holder

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Only on diesel engine

Slacken nut (1).

Release holder (2) from engine.

Fig 6: Releasing Holder From Engine

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Only on diesel engine

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

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

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Only on diesel engine

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

Fig 8: Identifying Screw And Cover Cap

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Release starter bolt (1) SW13 from above.

Release bolts (2) and remove starter.

Tightening torque 23 41 4AZ

Fig 9: Identifying Starter Bolts

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Supporting transmission:

Support gearbox 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 Gearbox 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: 43 ± 4 Nm

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 dowel sleeves (1) and (2) for correct seating.

Replace damaged fitting sleeves.

Fig 12: Identifying Adapter Sleeves

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Installation note:

Remove grease from transmission input shaft and clean shaft.

Do not grease transmission input shaft.

Check clutch disc for friction rust in gearing and REPLACE if necessary.

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 .