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

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: 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!

Release nuts (1) and remove clutch slave cylinder.

21 52 2AZ

Fig 4: Identifying Clutch Slave Cylinder Nuts

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Release screws (1).

Release holder (2) from engine.

Fig 5: Identifying Holder (2)

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Release starter bolt (1) WAF 13 from above.

Release bolts (2) and remove starter.

Tightening torque 12 41 4AZ

Supporting transmission:

Fig 6: Identifying Starter Bolts

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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 7: 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 23 00 1AZ

Fig 8: Locating Transmission Bolts

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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.

Installation note:

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

Replace damaged dowel sleeves.

Fig 9: 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 10: 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 .