Withdrawal
Raise the car.
Remove exhaust system (see section «Removal and installation of system of release of the fulfilled gases»).
Remove heat shield.
Unscrew the propeller shaft from the gearbox. For designs with integrated vibration damper, loosen the nuts on the propeller shaft disk.
Loosen the threaded ring with a pipe wrench (arrow) in the middle of the cardan shaft for a few turns.
Unbolt center bearing -A- for propshaft.
Tilt the cardan shaft down and pull it out of the centering pin.
Attention: Tie up cardan shaft.
With the propeller shaft removed, unhook retaining clip -1- from selector rod, remove washer -2- and pull out rod -3-.
Disconnect the reversing light switch wire from the rear of the transmission.
Unscrew the shift console from the rear of the gearbox.
Caution: Self-locking bolts are difficult to loosen.
On vehicles with a gear lever: use a screwdriver to remove the spring from the spout on the housing and move it back. You drag the supporting finger.
Remove clutch slave cylinder. Hydraulic drives remain connected (see section «Removal and installation of the clutch slave cylinder»).
On vehicles with OME (Motronic): Remove the heat shield. Pull out speed sensor -2- and reference mark sensor -3-.
Support the gearbox with a jack.
Remove cross bar.
Lower the gearbox to the front axle beam.
Loosen gearbox bolts using HAZET 880 insert wrenches -E10-, -E12-, -E14-.
Separate the gearbox from the engine and, together with an assistant, pull it down.
Installation
Check clutch before installing (see section «Removal and installation, clutch test»).
Check the ease of movement of the clutch release bearing. Lubricate the bearing, for example Liqui Moly M-320. If, when depressing the clutch, noises were previously observed during the operation of the bearing. replace release bearing (see section «Removal and installation of release bearing»).
Clean input shaft spline and spigot and lightly coat with Moly plain bearing paste or spray with Moly spray.
Turn on any transmission.
Raise the box and in a horizontal position, insert it into the clutch. If the input shaft does not fit into the clutch disc, turn the propeller shaft flange accordingly by hand.
Tighten the gearbox mounting bolts on the engine. Tightening torques: M18 bolts - 20 Nm; bolts M10 - 40 nm; M12 bolts - 70 nm.
Raise the gearbox and secure it to the transverse beam with a bolt torque of 25 Nm.
Vehicles with DME
Do not mix up the connectors, otherwise the engine will not start. Install the speed sensor -2- without the ring in the hole -D-, and the reference mark sensor -3- with the ring -4- in the hole -B-.
Before installing, check the O-rings. Insert sensors by coating them with Molykore Longtherm 2.
Caution: The front sides of the OME sensors must be clean and free of grease.
Install the clutch slave cylinder (see section «Removal and installation of the clutch slave cylinder»).
Variant with shift handle
Insert the support pin by coating it with Motykore Longtherm 2.
Push the spring -1- onto the spout -2- with the help of the spring.
Fasten the switch console with new self-locking screws with a tightening torque of 20 Nm. When tightening the bolts, ensure that the supports are horizontal with respect to the switching console.
Insert shift rod. Put a washer on the pin and fix the shift rod with a lock washer.
Connect the reversing light switch wire.
Install cardan shaft (see section «Removal and installation of cardan shaft»).
Install heat shield.
Install the exhaust system (see section «Removal and installation of system of release of the fulfilled gases»).
Check the oil level in the gearbox (see section «Checking the oil level in the gearbox»).