B284

Gearbox assembly B284 Continued





41. Remove the cables from the cable retainers by pulling back on the lock sleeves.
42. Unplug the connector of the reversing light switch and detach the gearbox ventilation hose.
43. Fit 30 07 739 Hose pinch-off pliers to the clutch hose and undo the quick-release coupling from the clutch slave cylinder.
44. Remove the upper bolts from the gearbox. Use 32 025 063 Special socket.





45. Fit 83 94 850 Lifting beam and 83 95 287 Holder with 32 025 037 Hook for lifting beam on the engine. Take the weight off the engine and gearbox.





46. 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.





47. Disconnect the ground lead.
48. Lower the power train with the lifting beam to facilitate removal of the transmission.
49. Raise the car and fit 87 92 608 Holder for single-column lift onto a column jack.
50. Fit 87 92 608 Holder for single-column lift on a column jack. Adjust and fasten the tool in the gearbox as illustrated.





51. Remove the lower retaining bolt of the secondary air pump.





52. Remove the lower bolts holding the gearbox to the engine.
53. Pull out and let down the gearbox.

Important: The jack can tip over. Be careful.

54. 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.
55. Plug the holes for the drive shafts if the gearbox is being transported or washed. Use 87 92 665 Protective plug, drive shaft hole

To fit
1. Make sure that the two guide sleeves are on the engine and apply grease to the sleeves. Lubricate the primary shaft.
2. Fit new drive shaft seals, lubricate them before fitting. Use 87 92 657 Fitting drift, drive shaft seals.
3. 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.
4. Fit 87 92 608 Holder for single-column lift onto a column jack.
5. Secure the tool to the transmission as for removal.

Important: The jack can tip over. Be careful.

Important: Slide in the gearbox until approx. 20 mm are remaining and remove the tool 83 95 162.

6. Fit the gearbox to the engine. Tighten the lower bolts between the engine and the gearbox.

Tightening torque, M10 bolts 40 Nm (30 ft. lbs.)

Tightening torque, M12 bolts 70 Nm (52 ft. lbs.)





7. Fit the lower retaining bolt of the secondary air pump.
8. Fit 83 95 162 Protective collar, drive shafts into the sealing ring. Lubricate the sealing ring.





9. Make sure that the drive shaft is clean and then align it with the tool.

Important: Fit the drive shaft 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.

10. Push in the rest of the shaft until the circlip clicks in.
11. Remove the lifting tool from the transmission and move away the jack. Fit the bolts into the transmission.

Tightening torque 22 Nm (16 ft. lbs.)

12. Lower the car to the floor.
13. Lift up the unit and fit the bracket on the engine mounting as marked earlier.

Tightening torque 70 Nm + 45° (52 ft. lbs. + 45°)





14. Remove the lifting beam and the holder.
15. Fit the ground cable.
16. Fit the upper bolts between the engine and the gearbox.

Tightening torque, M10 bolts 40 Nm (30 ft. lbs.)

Tightening torque, M12 bolts 70 Nm (52 ft. lbs.)





17. Put the wiring harness in place and fit the cable duct to the gearbox.





18. Fit the quick-release coupling to the clutch slave cylinder. Remove the hose pinch-off pliers. Make sure the connection is secured in the correct position. Bleed the clutch. See Bleeding the clutch hydraulic system in the car.
19. Attach the gearbox ventilation hose and plug in the connector of the reversing light switch.





20. Fit the cables to the cable retainers by pulling back on the locking sleeves.
21. Fit the gear cables to the gear selector arms.
22. Raise the car.
23. Fit the rear torque rod bracket to the gearbox.

Tightening torque 80 Nm (69 ft. lbs.)





24. Fit the front torque rod bracket to the gearbox.

Tightening torque 80 Nm (69 ft. lbs.)





25. Roll the trolley lift with subframe under the car.
26. Lift the frame. Position the suspension arm ball joints in the steering swivel member and the radiator guide pins. Make sure the upper radiator guides are against their brackets.