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

Special tools required:

Necessary preliminary tasks:

Disconnect BATTERY .
Diesel only: Remove the catalytic converter.
Drain off TRANSMISSION OIL .
Secure engine in INSTALLATION POSITION .
Remove TRANSMISSION SUPPORT BRACKET
Remove TRANSMISSION MOUNT .
Remove FRONT AXLE CARRIER
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 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.

Detach 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: 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 with diesel engine

Fig 5: Identifying Holder And Screws

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Only with diesel engine

Slacken nut (1).

Release holder (2) from engine.

Fig 6: Identifying Holder And Nut

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Only with diesel engine

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

Fig 7: Identifying Stud Bolts On Gearbox Side

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Only with diesel engine

Undo bolt (1) and remove protective cap (2).

Fig 8: Identifying Bolt And Protective Cap

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Undo starter bolt (1) SW13 from above.

Release bolts (2) and remove starter.

Tightening torque 12 41 1 AZ .

Fig 9: Identifying Starter Bolts

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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 repair work, check transmission oil level.

Fig 10: 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 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 Screws

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Installation note:

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

Replace damaged fitting sleeves.

Fig 12: 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 disc for friction rust in gearing and replace if necessary. See 21 21 500 REMOVING AND INSTALLING OR REPLACING CLUTCH or 21 21 500 REMOVING AND INSTALLING OR REPLACING CLUTCH (SAT 235) .

Fig 13: 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 and regrease.

In new clutch discs the gearing is already greased.
Remove and clean RELEASE BEARING AND RELEASE LEVER
Add TRANSMISSION FLUID .