Transmission Removal

IMPORTANT: Cables, hoses, leads, etc.., are secured with plastic cable ties. After being tightened, the excess part of the cable tie is cut off, resulting in more or less sharp ends remaining at the point of securement. Therefore, care must be taken to avoid injury.

To remove
1. Place the car on a lift.
2. Place covers over the wings to avoid damaging or dirtying the painters.





3. Remove the cover over the intake manifold, alternatively the resonator, together with hoses and mass air flow sensor.
4. Detach the battery leads from the battery.





5. Remove the battery.
6. Undo the battery negative lead on the gearbox.
7. Clean around the dipstick pipe entrance in the gearbox.





8. Remove the retaining nut and the cable mounting on the dipstick pipe.
9. Pull the dipstick and pipe straight up.
10. Plug the hole for the dipstick in the gearbox.
11. Remove the breather hose from the gearbox.
12. Remove the nut for the lever and lift the lever off the gearbox.
13. Undo the lock clip on the cable fitting.
14. Detach the cable ferrule from the fitting on the gearbox. Press in the locking catches with a screwdriver.





15. Unplug the electrical connections for the gearbox (located on a bracket behind the battery).
16. Unplug the electrical connection or connections to the oxygen sensor/s and detach it/them from the clamps.
17. Disconnect the positive cable mounting on the engine.





18. Remove the three upper bolts on the gearbox.
19. Take the strain off the engine and gearbox with lifting beam 83 94 850. Place the beam on the wheel housings so that it rests on the edges of the wings.
20. Raise the car.
21. Remove the front wheels.
22. Remove any clips for the oxygen sensor cable.





23. Remove the front exhaust system by first undoing the flange to the turbo and then undoing the rear mounting.
It is important that the exhaust system is dismantled in this way to prevent damaging the flexible pipe. Also, take care with the oxygen sensor/so.
24. Drain the fluid from the gearbox and refit the drain plug.
Tightening torque: 40 Nm





25. Disconnect the inlet and outlet hoses from the fluid cooler.
26. Plug the inlet and outlet passages on the gearbox as well as the hoses and bend them up. Plug: (10) 91 32 929, Seal: (10) 91
27. Remove the air shields and cover in the right-hand wheel housing.





28. Detach the end pieces from the suspensions arms on both sides. Use tool 89 96 696.
29. Remove the 2 nuts for the rear engine mounting and the two middle bolts for the subframe.





30. Place the lifting trolley 83 94 793 with parent fixture 83 94 801, front holder 83 94 819 and rear holder 83 90 827 under the subframe and raise the lifting trolley against the subframe.
31. Remove the remaining bolts securing the subframe. There are washers on the rear mountings, take care of them.
32. Lower the lifting trolley and push it to one side.
33. Detach the left-hand drive shaft from the gearbox by first releasing it from its splines and the carefully pulling it straight out by hand.
34. Use tool 89 96 654.





35. Remove the splash plate on the flywheel.
36. Undo the 6 bolts securing the torque converter to the drive plate.

NOTE: The crankshaft must be turned to access all the bolts.





37. Remove the rubber plug and fit special tool 87 92 277 to secure the torque converter in position while removing the gearbox.





Certain gearboxes do not have a hole in which to fit the tool. Therefore, drill a 5 mm hole and thread it with an M6 tap.
38. Unscrew the rear bolt in the mating surface engine/gearbox.





39. Remove the retaining bolts for the front engine mounting.
40. Remove the rear engine mounting from the gearbox.
Lower the car to the floor.
41. Lower the engine and gearbox with the lifting beam so that there is a play of about 1 mm between the body and the front mounting of the gearbox, the play can be observed from the front left wheel housing.
42. Raise the car.





43. Fit the lifting tool (MKM-886), part no. 87 92 608, onto a pillar jack.





Adjust the tool so that it is centered with the lifting lug on top of the gearbox and tighten it on the gearbox.





44. Remove the front bolt between the engine and the gearbox.
45. Pull out and lower the gearbox.

WARNING: The pillar-type jack may tip over. Exercise care.

46. Lift down the gearbox from the pillar jack with an engine lift at the same time as detaching the lifting tool from the gearbox.