Transmission, Removing
Transmission, removing
Special tools:
998 5972 JACK 998 5972 Jack
999 5716 Reading off tool 999 5716 Reading Off Tool
999 5259 SEPARATOR 999 5259 Separator
999 5460 Lifting hook 999 5460 Lifting Hook
999 5462 Jimmy tool 999 5462 Jimmy Tool
999 5463 FIXTURE 999 5463 Fixture
999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket
999 5972 FIXTURE 999 5972 Fixture
999 7077 Jimmy bar 999 7077 Jimmy Bar
999 7076 Lever 999 7076 Lever
999 7057 Counterhold 999 7057 Counterhold
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
999 5488 PLUGS 999 5488 Plugs
Disconnecting the battery lead
Remove the battery lead. See Battery, disconnecting Battery Disconnecting.
Removing engine compartment components
Remove:
- air filter housing complete with inlet manifold. Pull up the air filter housing from its attachments and undo the ground cable.
Applies only to turbocharged engines:
Remove the screws for the charge air pipe bracket on the inlet manifold.
Remove the charge air pipe from the intercooler.
Hint: Heat the pipe with a hot-air gun
Remove the screw from the hose clamp holding the cable harness.
Remove the vacuum hose from the clip at the air cleaner (ACL) bracket.
Removing the upper torque rod
Remove:
- the securing screws, 4, for the torque rod.
- the screw and nut for the engine mounting and torque rod
- the engine stabilizer brace.
Removing the coolant hose from the heater unit
Note! The hose is too short to be left in place when lowering the engine.
Turn the quick-release connector slightly in the direction of the arrow. At the same time, pull the hose towards you.
Collect the coolant that flows out.
Blocking the hose between the brake fluid reservoir and the clutch master cylinder
Remove the retaining clip from the clutch pipe junction.
Disconnect the pipe from the junction.
Note! Seal the openings against contamination. Wipe up any spilled brake fluid.
Removing the gear cables from the levers and attachments on the gearbox
Remove:
- cable conduit from the gearbox, 2 screws, 1 nut
Use jemmy bar 999 7077 Jimmy bar 999 7077 Jimmy Bar to detach the ball joint for the gear cable from the levers.
Detach the casing for the gearbox cables from the bracket in the gearbox by pressing the locking sleeve backwards.
Lift up the gearbox cables.
Tie up the gearbox cables.
Disconnect the connector from the reversing lamp switch.
Remove:
- the outer lever by knocking out the pin, move it over to the new gearbox
- the screws from the mechanical cable
- the bracket (from the gearbox).
Removing the mounting screws from the gearbox
Fold the cable conduit to one side.
Fold the hoses and the cable conduit out of the way of the engine and gearbox.
Remove:
- the 3 screws for the gearbox and engine
- the 2 screws for the starter motor
- the ignition setting sender. Pull it straight up slightly.
Installing the lifting beam and lifting hook on the engine lifting eyelet
Position lifting beam 999 5716 Reading off tool 999 5716 Reading Off Tool directly above the engine lifting eyelets.
Connect lifting hooks 999 5460 Lifting hook 999 5460 Lifting Hook
On the left-hand side: Tighten to light contact.
On the right-hand side: Leave a clearance of 5 mm.
Removing splash guards
Note! Position the front lift arms so that they do not obstruct the sub frame support plates.
Raise the car.
Remove:
- the front wheels
- the splash guard under the engine
- both the screws for the front splash guard. Press in the cover by press in the catches at the front edge of the cover. Pull the cover backwards.
Removing components around the sub-frame
Remove the screw from the cable conduit.
Removing links, tie rod and bolt for the drive shaft
Remove:
- link for anti-roll bar up on the spring strut (only left-hand side). Hold with Torx 30. Do not twist rubber boot.
- the screw for the drive shaft.
Removing the nut from the ball joint (both sides)
Remove the nut for the lower ball joint and control arm. Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut. Counterhold with Torx TX 40 at the ball joint pinion when removing the nut. This is so that the ball joint boot does not turn.
For steel control arm, see: Ball joint, replacing Service and Repair
Removing the screws from the sub-frame support plates (both sides)
Preparations for removal of the stub axle
- position mobile jack 998 5972 JACK 998 5972 Jack (applied lightly) under the right-hand side of the sub-frame
- slacken off both the sub-frame screws completely. Screw the screws back in approximately 5 turns
- release the sub-frame so that it rests on the screws and the mobile jack.
Removing stub axle from the control arm
Pry the control arm down. Use a lever999 7076 Lever 999 7076 Lever. At the same time, lift the stub axle off the control arm.
Note! Install socket 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket on the stub axle ball joint. Do not damage the rubber bellows for the ball joint.
Removing the drive shaft from the stub axle (right-hand side)
Grip the drive shaft. Pull the drive shaft down towards the control arm so that it does not tension.
Pull the brake disc outwards. At the same time, pull on the constant velocity joint towards the gearbox so that the drive shaft loosens.
Allow the drive shaft to lie on the control arm.
Removing the sealing ring for the CV joint housing from the stub axle
Remove the sealing ring for the constant velocity joint according to Seal CV joint housing, replacing Seal CV Joint Housing, Replacing.
Note! The sealing ring will be used again during installation.
Removing the cap for the drive shaft support bearing
Remove the screws from the bearing cap.
Removing the drive shaft
Take hold of the inner constant velocity joint. Pull the drive shaft straight out of the gearbox.
Note! Do not damage the seal.
Caution! Do not under any circumstances pull the outer section of the drive shaft in such a way that could cause the joints to separate. The joints do not have axial pinions.
Install the sealing plug 999 5488 PLUGS 999 5488 Plugs in the transmission.
Pressing up the sub-frame on the right-hand side
Press up the sub-frame on the right-hand side
Tighten the sub-frame screws to light contact. Then slacken off the screws approximately 4-5 turns.
Note! This is because the sub-frame hangs down more on one side.
Move the mobile jack to the left hand side.
Removing the screws for the torque rod from the gearbox
Remove:
- the screw for the front engine pad
- the screws for the torque rod from the gearbox.
Removing the cross members
Remove:
- the screws for the cross members
- the screws for the rubber mounting in the front cross member
- the brake pipe from its holders.
Removing the bracket for the power supply cable for the heated oxygen sensor (HO2S) from the sub-frame
Remove the screw from the bracket.
Removing the left drive shaft from the gearbox
Use jemmy tool 999 5462 Jimmy tool 999 5462 Jimmy Tool.
Note! Do not damage the seal.
Caution! Do not pull the drive shaft in a way that could cause the joints to separate. The joints do not have axial pinions.
Note! Applies only to cars with parking heaters: Remove the nuts for the heater from the sub-frame. Hang the heater on the left front wing.
Install the sealing plug 999 5488 PLUGS 999 5488 Plugs in the transmission.
Removal of the front propeller shaft, (Only applies to AWD)
Note! Mark the propeller shaft CV joint in relation to the bevel gear flange.
Remove the screws from the propeller shaft. Use counterhold 999 7057 Counterhold 999 7057 Counterhold.
Removing bevel gear
Remove the 5 angle gear bolts. Pull the angle gear straight out and hang it up with a cable tie as illustrated.
Removing the collision protection system over the steering gear (Only applies to right-hand drive vehicles)
Remove the screws and nut from the collision protection system.
Note! Carefully check that the collision protection system under the steering gear is free and not under stress.
Removing the screw for the rear engine pad
Lift up the anti-roll bar mounting. Use a jimmy bar. This will make it easier to position the tool and remove the screw.
Removing the rear engine mounting
Remove the 3 screws.
Lower the vehicle
Lowering the engine and transmission
Lower the engine-transmission on the left-hand side using the hook.
Lower the engine so that the distance between the lower edge of the mounting bracket and the spark plug cover is 250 mm.
Raise the vehicle
Preparations when removing gearbox
Remove the 2 nuts from the wing liner. Pull the wing away from the screws.
Drill out the 4 blind rivets in the front edge of the left wing liner.
Tie up the wing liner.
Installing fixture to mobile jack
Install fixture 999 5463 FIXTURE 999 5463 Fixture on fixture 999 5972 FIXTURE 999 5972 Fixture. Use the fixture and plate together with mobile jack 998 5972 JACK 998 5972 Jack.
Locate the fixture against the gearbox. Use support plate 9995463-2.
Tighten the fixture with the two torque rod screws.
Apply the mobile jack lightly against the gearbox.
Removing the gearbox
Remove all 7 screws securing the gearbox to the engine.
Pull the gearbox straight out in relation to the engine.
Note! Lower the transmission slightly when it is being removed so that it will pass the side member.
Continue pulling the gearbox straight out.
Caution! Follow the instructions above when dismantling the gearbox from the engine. Otherwise the centre of the disc can be deformed.