Withdrawal
Disconnect the ground wire from the battery with the ignition off. Remove the rubber seal on the plenum box. Remove the wiper arm and fairing. Remove both bolts -A- and three hexagon nuts -B-. Remove the fresh air intake duct towards the front.
Pull the safety mechanism on the selector cable and on the selector cable forward as far as it will go -arrow 1- and then lock it to the left -arrow 2-. Pull lock washer -arrow 3- off intermediate lever -A- and remove intermediate lever. Remove gearbox selector -B- by unscrewing nut -arrow 4-.
Detach pipe and hose line -A- from gearbox bracket. Remove clutch slave cylinder -B- and lay aside, secure with wire, do not open lines.
Instruction. Do not press the clutch pedal.
Unscrew the 2 bolts of the cable retainer from the gearbox -arrows-. The third bolt of the cable counterhold on the gearbox is removed from below with the vehicle raised. Remove the ground wire from the upper connecting screw securing the gearbox to the engine. Then unscrew the upper mounting bolt on the starter.
Install crosshead -10.222 A- together with adapter -10.222 A/13- and hook -10.222 A/12-. Connect adapter -10.222 A/13- at rear to securing hook for bonnet -arrow-. Tighten the engine with gearbox slightly using the spindles. Loosen the left front wheel bolts. Raise a / m. Remove left wheel. Remove soundproofing.
Unplug connector arrow -1- for starter. Unplug connector for reversing light switch -F4- arrow -2-. Remove bracket -A- from starter arrow -3-. Unscrew wire arrow -4- at solenoid relay, terminal 30. Remove starter.
Remove shield -1- from pendulum support -2-. Remove pendulum support -arrows A and B-. Detach drive shafts from gearbox flange shafts. Raise right drive shaft up and secure.
If fitted, unplug connector for speedometer sender -G22- -arrow-. Unscrew the third bolt -A- from the cable retainer on the gearbox. Then fasten the shift cable and the gear selection cable at the top. Unscrew connecting bolt -A- for engine/gearbox above right flange shaft.
Detach left stabilizer link -1-. Detach left arm from steering knuckle -arrow-. Remove fender liner on left wheel arch. Turn the steering knuckle out. Drive left drive shaft through opening between subframe and gearbox. In doing so, insert the drive shaft into the wheel arch and secure it to the spring strut, for example with a wire.
Disconnect wire -1- for lambda probe from heat shield -arrow A-. Unbolt bracket for exhaust system from underbody -arrows B-. Detach exhaust system at double clamp -2-. Secure the exhaust system to the heat shield using the T10038- harness.
Unscrew hexagon bolts -arrows- for power unit support (left-side) from gearbox housing. Tilt the drive unit, to do this, lower the crosshead -10.222 A- using the spindles. When lowering the power unit, ensure that the gearbox does not touch the power unit support in the area of the subframe. Bolts -arrows- of gearbox console -A- must be accessible.
Remove gearbox console -A- -arrows-. Assemble tilter with gearbox bracket -3282-, adjusting template -3282/31- for gearbox "02T" and fasteners as follows: Place adjusting template -3282/31- on gearbox bracket -3282-. (Adjustment template has only one mounting position). Position the gearbox bracket catches in accordance with the holes in the adjustment template.
Screw fasteners -A- onto the adjustment template as shown in fig.
Position the turntable under the vehicle, the arrow symbol -B- on the setting template indicates the direction of travel of the vehicle. Align the adjustment template parallel to the BC and fix the fixing support on it. Unscrew the lower connecting screws of the gearbox to the engine. Remove connecting bolts for engine/gearbox connection -arrow-. Press the gearbox off the fitted bushings and tilt carefully towards the subframe. Carefully move the engine forward with the help of a second mechanic. Turn the gearbox in the differential area down.
Then carefully lower the gearbox, while guiding it with the right flange shaft -A- as shown in the area of the flywheel and the left flange shaft -B- in the area of the subframe. Change the position of the gearbox when lowering with the spindles of the mounting bracket -3282-.
Installation
The installation of the gearbox is carried out in the reverse order. At the same time, install the pillow of the power unit without tension.
Instruction. Clean input shaft splines and apply a thin coat of spline grease for clutch disc -G 000 100-. When replacing the gearbox, pay attention to the correct installation of the metal spacer. Check the presence of fitted bushings in the cylinder block for centering the engine / gearbox, insert bushings if necessary. Check transmission oil. Install starter/wire. Attach the strut to the stabilizer and the arm to the steering knuckle. Adjust gearshift mechanism. After connecting the battery, check and activate all vehicle systems (radio, clock, electrics of the Comfort system).
Tightening torques
Gearbox to engine
Pos. | Bolt | PC. | Nm |
1 1) | M 12x65 | 1 | 80 |
2 2) | M12X140 | 2 | 80 |
3 | M 12x80 | 1 | 80 |
4 | M 10x50 | 2 | 45 |
5 | M 12x65 | 1 | 80 |
A | Centering sleeves |
1) Bolt with grub screw M8
2) Additionally starter for gearbox
Gearbox console -A- to gearbox
Replace bolts. Bolts -arrows- 50 Nm and turn 90°further.
Gearbox to body
Replace bolts. Bolts -arrows- 40 Nm and turn 90°further.
Lower support of the power unit
Replace bolts. Bolt -A-: 40 Nm and turn 90°further. Bolts -B-: 50 Nm.
- Cable stops to gearbox: 20 Nm
- Gearshift lever to gearbox: 20 Nm 1)
- Slave cylinder to gearbox: 23 Nm
- Double clamp to exhaust pipe: 40 Nm
- Screen to pendulum support: 23 Nm
1) Replace nut.
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