Shift Cable: Service and Repair

Transmission cable, replacing

Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Removal

Removing the air cleaner (ACL) housing




The air cleaner housing (ACL) assembly with the intake pipe. Pull the air cleaner (ACL) housing out of its mountings.

Remove:
- the left front wheel
- the 2 plastic nuts for the fender liner. Remove the splash guard over the drive shaft.

Remove the gear selector cables from bracket and the lever at the transmission





Remove:
- the catches at the levers
- the retaining clips from the bracket for the mechanical cables. Pull the retaining clips straight up
- the mechanical cables.

Note! The color coding on the outer cable.

Removing the center console
Remove the center console. See Center console, replacing Center Console, Replacing.

Removing the gear selector assembly and cables





Remove:
- the screws for the gear selector assembly
- the catches for the mechanical cables from the gear selector lever and transmission lever. One catch is positioned under the gear selector assembly
- the mechanical cables from the gear selector assembly nose. Pry up the cable
- the gear selector assembly.

Removing the cables at the firewall




Fold and roll the carpet under the accelerator pedal (AP). Fold and roll the carpet under the accelerator pedal (AP).

Remove:
- the two nuts for the transmission cable grommet at the firewall
- the cables by drawing them into the passenger compartment.

Hint: Route the mechanical cables correctly in the engine compartment with someone to assist you.

Installation

Note! For tightening torques, see applicable specifications.

Preparations for installing the mechanical cables




Bend a heavy welding rod (wire).
Tape the ends of the mechanical cables together.

Note! When installing mechanical cables: Be careful to ensure that there are no sharp bends or kinks in the mechanical cable, especially between the inner mechanical cable and outer sleeve.

Hint: Route the mechanical cables correctly in the engine compartment with someone to assist you.

Installing the cables from the inside of the passenger compartment




Install the mechanical cables under the heater unit on the left-hand side, down towards the hole.

Note! Be extremely careful when running the rubber bellows for the mechanical cable through the hole in the firewall. The cables must not be damaged.

Feed the mechanical cables through the hole slightly.

Hint: Ask a colleague to hook the end of the cable onto the welding rod (wire).

Locate the grommet on the studs
Install the nuts. Tighten to 12 Nm.

Feeding in the mechanical cable from the engine compartment




Pull the welding rod (wire) while feeding the cable in from the inside.
The cable must be routed past the steering gear and up to the transmission bracket.

Positioning the mechanical cables behind the steering gear




Position the mechanical cables behind the steering gear and over the hydraulic pipe.
Install the splash guard and the plastic nuts for the fender liner.

Installing the gear selector cables on the transmission





Note! Connect the yellow marked cable to the outer hole in the bracket and the outer lever on the transmission.

Install:
- the mechanical cables for the transmission on the bracket with retaining clips
- the mechanical cables for the transmission on the transmission levers with the catches.

Installing service clips





Note! The automatic transmission has a gear selector cable while the manual transmission has two gear selector cables.

Ensure that the gear selector cable is engaged before fitting the blue clip. Press the clip into position as illustrated.




Check that the clip is positioned in the groove as illustrated.

Installing the air cleaner (ACL) housing
Install the air cleaner (ACL) housing, including all hoses and electrical terminals. Tighten the hose clamp.

Installing the front wheel
Install the front wheel. See Installing wheels Service and Repair.

Installing the cables and gear selector assembly





Install:
- the mechanical cables on the levers on the gear selector assembly. Use the catches
- the mechanical cables on the gear selector nose

Installing service clips





Note! The automatic transmission has a gear selector cable while the manual transmission has two gear selector cables.

Ensure that the gear selector cable is engaged before fitting the blue clip. Press the clip into position as illustrated.




Check that the clip is positioned in the groove as illustrated.

Install the following items:
- the gear selector assembly to the bodywork. Tighten to 25 Nm
- the connector on the gear selector assembly.
Check that the gear positions are working.

Installing the center console
Install the center console. See Center console, replacing Center Console, Replacing.