Removing Components From the Transmission

Removing components from the transmission
Remove:





- the hose from the charge air pipe. Move the hose to one side
- the oil line from the transmission and the oil cooler.

Hint: The quick-release connector for the oil cooler is detached by pressing the connection housing for the oil line towards the oil cooler. Hold the connection housing in this position. Pull back the lugs on the connection housing. Pull the connector off the oil cooler.

Seal the hole in the transmission with a plastic plug.

Removing screws





Remove all screws for the control system cover.
Leave the cover in place.
Clean any sealing compound from the threads.
Use tap M8 x 1.25.

Removing the cover for the control system





Remove the cover.
Use removal tool 999 5477. Tap the tool carefully into the joint between the cover and the transmission to ensure that the cover sealing flange is not distorted.

Checking and cleaning





Clean the gasket residue from the cover and the transmission.

Note: Ensure that no debris enters the transmission. Wash the cover thoroughly.

Check that the mating surface for the cover is level.

Installation
Applying liquid seal





Wipe the cleaned mating surfaces on the cover and transmission. Use isopropyl alcohol. Apply an approximately 3 mm thick bead of liquid sealant (P/N 116 1409-6) to the cover. Also apply sealant around the screw holes.

Installing the control system cover
Reinstall the control system cover on the transmission.





Ensure that the liquid gasket is not rubbed off when installing the cover.
Use new screws. Tighten the screws alternately to contact. Tighten. See: Specifications.

Installing components
Install:





- the oil line with the quick-release connector to the oil cooler
- the oil line to the transmission. Use a new O- ring. Tighten the screw. See: Specifications
- the hose to the charge air pipe.

Filling with oil

Caution: Absolute cleanliness is essential during this work.

Note: Use only transmission oil, P/N 116 15408 (1 l liter container), 116 1640-6 (4 liter container).





Fill with new oil to the volume previously noted.
Fill with oil through the connector sleeve for the return line in the transmission cover.
Install the oil return pipe for the oil cooler and the cover on the transmission. Check the oil level. See: Oil level, checking