B207
Gearbox assembly B207 Continued41. Detach the ABS cable from the clip using a screwdriver and undo the left-hand drive shaft using 87 92 616 Removal tool, drive shafts.
42. Suspend the shaft with a 83 95 212 Strap.
43. Lower the car, mark the positions of the bolts on the left-hand engine bracket with a marker pen for correct refitting and then remove the bolts from the mounting.
44. Lower the drive unit approx. 70 mm from the lifting beam to facilitate the removal of the gearbox. Measure the distance at the left-hand engine mounting.
45. Raise the car.
46. Fit 87 92 608 Holder for single-column lift on a column jack. Adjust and fasten the tool in the gearbox as illustrated.
47. Remove the last bolt, pull out the transmission and lower it.
Important: The jack can tip over. Be careful.
48. Lift the transmission down from the column jack with an engine lift and 87 92 442 Lifting cable while undoing the lifting tool from the transmission.
49. Plug the holes for the drive shafts with 87 92 665 Protective plug, drive shaft hole if the gearbox is to be transported any distance.
To fit
1. If necessary, perform the procedure Bleeding the slave cylinder.
2. Lubricate the primary shaft splines, see List of lubricants and sealants.
3. Lubricate the guide sleeves on the engine with anti-corrosion agent.
4. Fit 83 95 162 Protective collar, drive shafts in the right shaft seal in the transmission. This is done to protect the seal while the transmission is being fitted. Lubricate the seal.
Important: Always replace the shaft seals in the gearbox. Lubricate with gearbox oil.
5. Fit the gearbox with the lifting tool on the column jack.
Important: Make sure the gear cables are positioned correctly when lifting the gearbox.
Important: Slide in the gearbox until approx. 20 mm are remaining and remove the tool 83 95 162.
6. Push in the rest of the gearbox. Turn the crankshaft if necessary to get the gearbox in place.
7. Tighten all bolts except the top one between the engine and the gearbox.
Tightening torque, M10 bolts 40 Nm (30 ft. lbs.)
Tightening torque, M12 bolts 70 Nm (52 ft. lbs.)
8. Fit the charge air pipe bracket.
9. Remove the lifting tool from the gearbox and move away the jack.
10. Lower the car. Lift in place the power train with the lifting beam until it meets the engine mounting.
11. Fit the bracket for the engine mounting according to the marks made earlier.
Tightening torque 70 Nm + 45° (52 ft. lbs. + 45°)
12. Remove the holder, lifting beam and lifting eyes.
13. Fit the coolant reservoir.
14. Fit the upper bolts to the gearbox.
Tightening torque 70 Nm (52 ft. lbs.)
15. Raise the car.
16. Fit 83 95 162 Protective collar, drive shafts in the left drive shaft seal. Remove the strap. Make sure that the drive shaft is clean, lubricate it and then align it with the tool.
Important: Fit the driver in the gearbox until approx.20 mm are remaining and pull out the tool before the sealing surface of the shaft reaches the shaft seal.
17. Push in the rest of the drive shaft into the gearbox until the circlip clicks in.
18. Attach the ABS cable to the clip.
19. Remove the oil filler plug and fill with 2.2 l of oil. See List of lubricants and sealants. Fit the filler plug.
Tightening torque 45 Nm (33 ft. lbs.)
20. Fit the two torque rod brackets.
Tightening torque 80 Nm (59 ft. lbs.)
21. Position the subframe with the help of the fixture. Raise until it is possible to fit the anti-roll bar to the subframe.
22. Fit the anti-roll bar to the subframe.
Tightening torque 18 Nm (13 ft. lbs.)
23. Fit the suspension arm ball joints to the steering swivel member.
Tightening torque 50 Nm (37 ft. lbs.)
Important: Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.
24. Check that the guide pins fit into the reference holes, adjust the subframe: until the guide pins go in easily and fit the subframe: bolts and brackets.
Tightening torque, subframe: 75 Nm + 135° (55 ft. lbs. + 135°)
Tightening torque, rear subframe bolts: 90 Nm + 45° (66 ft. lbs. + 45°)
25. Connect the connector and the cable clip to the headlamp angle sensor (optional).
26. Move away the trolley lift and jig.