Remove the manual transmission

WARNING: Car may slip off the vehicle hoist where components are supported.
Danger! Immobilization period-threatening injuries!

Secure the vehicle hoist against lowering and lifting.
Make sure that the vehicle does not lift off the mounting plates on the vehicle lift.

WARNING: Car may slip off the vehicle hoist if the weight is distributed unevenly.
Danger! Immobilization period-threatening injuries!

Ensure there is a specific weight compensation on the car.

WARNING: Vehicle may slip off the vehicle hoist if the vehicle hoist is handled incorrectly.
Danger! Immobilization period-threatening injuries!

Observe safety instructions on raising the vehicle using a vehicle hoist.
For additional information see: 00... RAISE THE VEHICLE USING A VEHICLE LIFT .

Preliminary work

Refer to REMOVING THE ACOUSTIC COVER .
Refer to REMOVING INTAKE PORT .
Refer to REMOVING INTAKE SILENCER HOUSING .
Refer to REMOVING LEFT AND RIGHT WIPER ARM .
Refer to REMOVING REAR HOOD SEAL .
Refer to REMOVING LEFT WINDSHIELD PANEL COVER .
Refer to REMOVING RIGHT WINDSHIELD PANEL COVER .
Refer to REMOVING THE SECOND FIREWALL AT TOP .
Refer to REMOVING BATTERY COVER .
Refer to REMOVING BATTERY .
Refer to MOVING THE ENGINE TO THE INSTALLATION POSITION .
Refer to DETACHING STEERING SHAFT AT BOTTOM FROM STEERING GEAR .
Refer to MOUNTING THE COOLANT RADIATOR ON THE LEFT AND RIGHT .
Refer to REMOVING THE FRONT LEFT AND RIGHT WHEELS .
Refer to IF INSTALLED: REMOVING REAR UNDERBODY PROTECTION .
Refer to REMOVING THE FRONT LEFT AND RIGHT WHEEL ARCH COVER .
Refer to DETACHING THE CABLE FOR THE RIDE HEIGHT SENSOR .
Refer to RELEASING THE LEFT AND RIGHT ANTI-ROLL BAR FROM THE ANTI-ROLL BAR LINK .
Refer to DETACHING RUBBER MOUNT FROM FRONT AXLE SUPPORT .
Refer to DISCONNECTING PLUG CONNECTIONS FROM STEERING GEAR .
Refer to DISCONNECTING THE PURGE AIR LINE
Refer to RELEASING THE MOUNTED PARTS FROM THE FRONT AXLE SUPPORT .
Refer to COMPLETELY RELEASING AND REMOVING THE FRONT AXLE .
Refer to REMOVING STARTER MOTOR .
Refer to REMOVING LEFT OUTPUT SHAFT AT TRANSMISSION END AND HANGING UP .
Refer to REMOVING RIGHT OUTPUT SHAFT AT TRANSMISSION END AND HANGING UP .
Refer to REMOVING THE LEFT/RIGHT RADIAL SHAFT SEAL ON THE DIFFERENTIAL (GS6-58BG) .

CAUTION: Materials harmful to health.
Contact with fluids harmful to health!

Note and follow safety instructions on containers.
Conduct all work in appropriate personal protective equipment only.

NOTE: RISK OF DAMAGE
Damage to the engine block.
Serious damage to the engine block and transmission due to damaged and corroded screws.

It is imperative that protruding threads of the transmission bolts are checked for corrosion and damage prior to removal.
It is imperative that all rust is removed from corroded threads and that they are cleaned prior to removal.
Replace rusted and damaged bolts.

Remove E-box

Precondition

Battery ground lead is disconnected.

NOTE: RISK OF DAMAGE
Electrostatic discharge.
Damage to or destruction of electrical components.

Leave the electrical components in their original packaging until they are being installed. Only use the original packaging for returning the product. Always package removed components straight away.
Read and comply with user information on using the associated special tool 12 7 060.
Only tap the housings of electrical components. Do not tap pins or multi-pin connectors directly.
Wear electrically conductive clothing and antistatic shoes (with ESD symbol).
For additional information see: 61 35... NOTES ON ESD (ELECTROSTATIC DISCHARGE) PROTECTION

NOTE: RISK OF DAMAGE
Damage to wires when disconnecting connectors and plug connections.
Sheared wires can cause a short circuit.

Do not pull on wires when disconnecting connectors and plug connections.

Detach positive battery terminal (1).
Guide out the battery positive terminal (1) and place to the side.
Guide the positive battery cable (2) out of the holder (3) and lay to one side.

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Loosen screw (1).
Unlock the cover (2) and feed out of the guides (3) in the direction of the arrow and remove.

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Guide out and remove plug connection (1) from E-Box (2) in the arrow direction.
Unlock plug connection (1) and disconnect.

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Unlock and release plug connections (1) in the arrow direction.
Feed out connector (1) and place to one side.

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Unlock plug connections (1) and disconnect.

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Thread out positive battery cable (1) and set it aside.
Unlock lock (2).
Guide out wiring harness section (3) for the injectors and the ignition coils in the arrow direction and set aside.

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Unlock the locks (1).
Feed out the wiring harness section (2) for the Valvetronic servomotor in the direction of the arrow and set aside.

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Unlock the locks (1).
Feed out the wiring harness section (2) for the engine in arrow direction and set aside.

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Unlock and loosen holder (1).
Thread the holder (1) in direction of arrow out of the E-box (2) and set aside.

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Loosen screw (1).

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Thread E-box (1) in direction of arrow out of the guide (2) and remove.

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Remove battery carrier
Detach cable clip (1) from battery carrier (5).
Detach coolant line (2) from battery carrier (5).
Loosen screws (3).
Loosen screw (4).
Feed out battery carrier (5) and remove.

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Release the clip at the stop/holder (2) while slightly bending the lugs away from the stop/holder (2).
Release the screw (1) and release the ground strap from the transmission.

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Lever off the insert fixtures (3) of the selector lever cables from the ball joints using a size 13 open-end wrench.

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Unlock and disconnect the plug connection (2) of the gear sensor.
Release the cable (1) with the holder from the transmission.

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Relieve tension on clutch slave cylinder slowly; otherwise air will be drawn in through seal cup.
Pressure line of clutch slave cylinder remains connected.
Release the screws (1) and remove the clutch slave cylinder.

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Loosen screws (1).

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Loosen screws (1).

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Support the transmission using special tools 0 490 133 (00 2 030) and 0 495 827 (23 4 150) .
Secure the transmission with the luggage strap (3).

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Remove screws (arrows).
Pull transmission downwards and remove.

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Check the fitting sleeves (1) for correct seating and damage and replace if necessary.

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Remove grease from transmission input shaft (arrow) and clean it.
Do not grease the transmission input shaft (arrow).
Check clutch disc for contact corrosion in gearing and replace if necessary.

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