23 00 026 Removing and installing transmission (GS6-55BG)

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 .

Release clips on stop/holder (1).

Detach selector lever cable (2) from ball joint.

Release screw (3) and remove bracket.

Fig 1: Stop/Holder, Selector Lever Cable And Screw

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Disconnect plug (1) for reversing light switch.

Fig 2: Plug For Reversing Light Switch

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

Remove cable (2) with holder from transmission.

Fig 3: Identifying Cable With Plug Connection

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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 sleeve.

Release nuts (1) and remove clutch slave cylinder.

Tightening torque 21 52 2AZ

Fig 4: Clutch Slave Cylinder Nuts

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Release bolt (1) WAF 13 from above.

Release bolts (2) and remove starter.

Tightening torque 12 41 1AZ

Fig 5: Starter Bolt

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Supporting 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 6: Tensioning Strap And Special Tools (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 7: Locating Screws

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Installation note:

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

Replace damaged dowel sleeves.

Fig 8: 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 9: Checking Lubrication At Input Shaft

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Installation note:

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

Clean clutch hub and regrease.

On new clutch discs the gearing is already greased.

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