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

Special tools required:

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 Selector Lever Cable, Holder And Screw

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Disconnect plug (1) for reversing light switch.

Fig 2: Identifying Reversing Light Switch Plug

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

Remove cable (2) with holder from transmission.

Fig 3: Identifying Zero Gear Sensor Plug Connection And Cable

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NOTE: Pressure line of clutch slave cylinder remains connected.

IMPORTANT: 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 therefore not necessary.

Release nuts (1) and remove clutch slave cylinder.

Tightening torque 21 52 2AZ .

Fig 4: Identifying Clutch Slave Cylinder Nuts

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Release bolt (1) WAF 13 from above.

Release bolts (2) and remove starter.

Tightening torque 12 411 AZ .

Fig 5: Identifying Starter Bolts

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Supporting transmission:

Using 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 fluid level.

Fig 6: Supporting Transmission From Underneath Using Special Tools (23 4 150) And (00 2 030)

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NOTE: There is no bolt fitted at the lowest 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 Transmission Screws

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Installation note:

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

Replace damaged fitting sleeves.

Fig 8: Identifying Dowel Sleeves

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Installation note:

Remove grease from transmission input shaft and clean shaft.

Do not grease transmission input shaft.

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

Fig 9: Locating Transmission 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 c.

On new clutch plates the splines are already greased.
Remove and clean RELEASE BEARING AND RELEASE LEVER
Add TRANSMISSION OIL .