Remove/install transmission

AR26.10-S-0020B

Remove/install transmission

11.11.11

 

Remove/install

1

Disconnect ground lead from battery

 Installation: Code radio.
Set timer.

AR54.10-S-0005A



Notes on battery

AH54.10-P-0001-01A

2

Remove front wheels

AR40.10-S-1100A

3

Detach protective cover of belt pulley

AR94.30-S-5300A

4

Drain transmission oil

AP26.00-D-2601A

5

Remove right and left drive shaft from transmission

 Secure the drive shafts.

AR33.30-S-6500M

6

Disconnect electrical connections on transmission

AR26.19-S-0001-05A

7

Unscrew nut securing power lines to connection box

 Install new self-locking nut.

8

Disconnect connectors in connection box

9

Detach connection box from windshield washer reservoir

10

Detach shift cables from transmission.

AR26.60-S-6627-01A

 Danger!

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A

11

Disconnect pressure hose from central clutch release bearing

 Installation: The safety clamp must be installed before inserting the pressure hose.

 Collect escaping brake fluid.

12

Unscrew nut of mounting clamp securing pressure hose on transmission



*BA25.20-N-1003-01D

13

Unbolt center drive shaft from transmission

 Slide the center drive shaft out of the transmission. Seal the opening using a rag.

AR33.30-S-7706C

14

Detach left transverse control arm (7) on longitudinal axle member part (3) from axle/engine subframe and on kingpin and release threaded connection of rubber mount (8) from transverse control arm (7)

 Swing the transverse control arm (7) out of the way; do not damage the dust caps.

The transverse control arm (7) remains attached to the axle/engine subframe.

AR33.20-S-1452M

15

Unbolt bracket for power steering fluid reservoir and air conditioning reservoir from lock crossmember

AR88.00-S-2302A

16

Disconnect hose connection from left windshield washer nozzle

17

Insert engine holding device, attach to support on engine and tension slightly

Engine support device, engine hoist
gotis://A_01_09.0

18

Unscrew bolt (5) from transmission mount



*BA22.10-N-1004-01I

19

Lower engine using engine holding device

 When lowering, do not damage the power steering hydraulic line between the axle/engine subframe and oil pan.

20

Remove exhaust collector pipe from catalytic converter

AR14.10-S-3920A

21

Unscrew bolts (2) from transmission housing



*BA26.10-N-1001-01F

22

Remove transmission (1)

 Clean the inside of the transmission bell housing using a rag.

23

Detach left drive flange on transmission

 Only when replacing the transmission.

AR33.30-S-1000A

24

Install in the reverse order

25

Bleed the clutch

AR25.20-S-0070B



Checking

26

Check transmission oil level, correct if necessary

Number

Designation

Model 638 with engine 611.980

BA22.10-N-1004-01I

Bolt, left engine support to transmission

Nm

120

Number

Designation

Engine
611.980

BA25.20-N-1003-01D

Clamp, hydraulic line to transmission housing

Nm

16

Number

Designation

Model 638 with engine 611.980 without code G40

BA26.10-N-1001-01F

Bolt, manual transmission to engine

Nm

53