Gearbox Cables, Replacing

Gearbox cables, 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

Remove:
- the fresh air intake hose
- the air cleaner (ACL) housing assembly with the intake pipe.

Remove the mechanical gear selector cables from the bracket and the levers on the gearbox

Remove:
- the gear selector cables from the levers. Use jimmy bar 999 7077 Jimmy bar 999 7077 Jimmy Bar
- the mechanical cables from the bracket by moving the sleeves back on the cable sleeves.

Removing centre tunnel console
Remove the centre console. See Center console, replacing Service and Repair.

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

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.

Preparations for installing the mechanical cables
Secure a cable using tape to the engine compartment end of the mechanical cable before pulling it out to make reinstallation easier

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 centre console when removing the gear selector cable.

Installation

Note! For tightening torques, see Tightening Torque

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: Have a colleague pull through the pre-routed cable.

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
Use the cable to correctly route the gear selector cables. The gear selector cable must be routed past the steering gear and up to the gearbox bracket.

Installing the centre tunnel console
Install the centre console. See Center console, replacing Service and Repair.

Installing the gear selector cables on the gearbox

Note! Connect the gear selector cable with the white sleeve to the inner hole on the bracket and the inner lever to the gearbox.

Release the adjuster on the mechanical cable before installing it.

Install:
- the gear selector cables on the bracket
- the outer gear selector cable on the gear selector cable. Press into place by hand.

Check that the gear selector lever is in neutral.

Install the inner gear selector cable on the lever. Press into place by hand.
Press the adjuster into place so that it is locked on the cable.

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.

Final check
Check that the gear positions are working.