M56 Transmission

Transmission cable, replacing

Special tools:
999 7071 Puller 999 7071 Puller
999 7077 Jimmy bar 999 7077 Jimmy Bar

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 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.

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

Remove:
- the gear selector cables at the levers. Use tool 999 7077 Jimmy bar 999 7077 Jimmy Bar
- the cable sleeves from the brackets by moving the sleeves back on the cables.

Removing the center console

S60R (B5254T4 engine)
Remove the center console. See Center console, replacing Center Console, Replacing.

S60 (other engines)
Remove the center console. See Center console, replacing Center Console, Replacing (-2004) or Center console, replacing Center Console, Replacing (2005-).

Removing the rubber lead-in

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 grommet for the gear selector cables at the firewall. Pull the gear selector cables approximately 10 cm into the passenger compartment.

Hint: Route the gear selector cables correctly in the engine compartment with the assistance of another person.

Removing the gear selector cable from the ball joint

Remove:
- the connector
- the screws for the gear selector assembly.
Lift the gear selector assembly and twist it so that the lower gear selector cable is accessible.

Removing the gear selector cable from the ball joint and gear selector assembly

Remove the gear selector cable from the ball joint. Use puller 999 7071 Puller 999 7071 Puller.

Hint: The screw on the puller is turned counter-clockwise to pull the gear selector cable loose.

Carefully pry up the catches (1) and slide the cable sleeves upwards on both the gear selector cables.
Remove the gear selector assembly.

Removing the gear selector cables
Pull the gear selector cables straight out.

Hint: It is easier taking one gear selector cable through the firewall at a time.

Hint: Do not damage the cable harnesses in the center console when removing the gear selector cable.

Installation

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 gear selector cables from the inside of the passenger compartment

Install the gear selector cables under the heater unit on the left-hand side, down towards the hole in the firewall.

Note! Be extremely careful when running the rubber bellows for the gear selector cables through the hole in the firewall. Do not damage the gear selector cables.

Feed the gear selector cables through the hole slightly.

Hint: Ask a colleague to hook the end of the gear selector cable onto the welding rod.

Pull out the gear selector cables so that the rubber grommet is approximately 10 cm from the firewall.

Installing the gear selector cables and gear selector assembly

Install:
- the gear selector cables on the levers on the gear selector assembly. Press into place by hand
- the sleeves for the gear selector cables on the gear selector assembly
- the gear selector assembly on the bodywork (M8)
- the connector on the gear selector assembly.

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 rubber grommet
Align the grommet on the studs. Install the M6 nuts.

Feeding in the gear selector cable from the engine compartment

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

Positioning the gear selector cables behind the steering gear

Position the gear selector cables behind the steering gear and above the hydraulic pipes.
Install the splash guard and the plastic nuts for the fender liner.

Installing the gear selector cables on the transmission

Note! Connect the gear selector cable with the white sleeve to the outer hole in the bracket and the outer lever to the transmission.

Install:
- the gear selector cables on the bracket
- the gear selector cables on the transmission levers. Press into place by hand.

Installing service clips

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.

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

Installing the center console

S60R (B5254T4 engine)
Install the center console. See Center console, replacing Center Console, Replacing.

S60 (other engines)
Install the center console. See Center console, replacing Center Console, Replacing (-2004) or Center console, replacing Center Console, Replacing (2005-).

Final check
Check that the gear positions are working.