Shift Actuator: Service and Repair

Removing and Installing/Replacing Actuator (S6S 420G SMG)

Special Tools Required:
- 00 2 030
- 23 0 040
- 23 0 240
- 00 2 030
- 23 0 040
- 23 0 240

NOTE:
After completing work:
- Proceed according to test program, refer to "Service Functions" in DIS Tester.
- Read out fault memory and clear fault entries.
- Check fluid level in hydraulic system.

Necessary Preliminary Tasks:
- Depressurize hydraulic system. Procedures
- Disconnect battery, battery positive lead from battery terminal. Instructions For Disconnecting and Connecting Battery
- Remove intake air manifold.
- Remove fan with fan impeller. Service and Repair
- Remove underbody protection.
- Remove catalytic converter and intermediate pipes. and






Remove middle heat shield (1).






Remove side heat shield (1).

Remove bracket for underbody protection at rear.





Release screws.

Installation:
- Replace self-locking nuts.
























- Tighten Torque, 26 11 1AZ.






Grip propeller shaft and release nuts.

Installation:
























- Tightening torque, 26 11 6AZ

Bend propeller shaft downwards at center bearing (1).

Detach propeller shaft from transmission output flange and tie back to side on vehicle underbody.





Support transmission with special tool 00 2 030, 23 0 040 (23 0 041 and 23 0 042).






Release screws and remove cross-member (1).

Installation:



- Tightening Torque: 23 71 1AZ/2AZ.


Lower transmission until cylinder head touches bulkhead.

Support engine at front.

Installation:
- Observe position of vibration damper (2).





Disconnect plugs (4) and (5).

Unclip cable at holders





Lever out retaining ring (1) with a screwdriver.

Slide retaining ring (1) forwards slightly.






Drive out retaining pin (1) on selector rod linkage with special tool 23 0 240.

Note:
To remove retaining pin (1): slide selector rod into transmission.






Release screws on actuator.

Installation:
- Insert screws with Loctite 243









- Tightening Torque, 23 41 1AZ






Release union screws (1...3) of hydraulic lines on actuator.

Installation:






- Tightening Torque 21 52 7AZ.





Release screw (1).

Installation:
- Replace screws (1).

Release screw (2) on actuator.

Installation:









- Tightening Torque 23 41 4AZ.

Remove actuator.