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PRE-RELEASE

Complete gearbox, B284 4WD

Complete gearbox, B284 4WD

To remove


1. Place covers over the wings to keep the paintwork clean and protect it from damage.

2. Remove the upper engine cover.

3. Remove Battery cover, lower section, B284 .

4. Lift up the expansion tank (A).


5. Remove the upper heat shield (A) from the catalytic converter.


6. Remove the lower heat shield (B) from the catalytic converter.

7. Remove the turbo delivery hose (A) from the turbo.


8. Remove the cable duct (A) from the gearbox.


9. Remove the gear cables (A) from the gear selector arms.


10. Remove the cables from the cable retainers by pulling back on the lock sleeves.

11. Unplug the connector for the reversing light switch (B).

12. Fit 30 07 739 Hose pinch-off pliers to the clutch hose and undo the quick-release coupling from the clutch slave cylinder.

13. Remove the upper bolts (A) from the gearbox. Use 32 025 063 Special socket .


14. Fit 83 94 850 Lifting beam and 83 95 287 Holder with 32 025 037 lifting yoke hook on the engine. Make sure that the hooks are screwed into the fork holder at least 10 mm. Relieve the load on the engine and gearbox.


15. Mark the location of the bolts on the left-hand engine bracket with a marker pen for correct refitting and remove the bolts (A) from the bracket.


16. Remove Transfer case .

17. Loosen the left-hand drive shaft (A) using 87 92 616 Removal tool, drive shafts .


18. Hang up the shaft with 83 95 212 Strap .

19. Lower the car to the floor.

20. Lower the power train with the lifting beam to facilitate removal of the transmission.

21. Raise the car and fit 87 92 608 Holder for single-column lift onto a column jack. Adjust and secure the tool in the transmission as illustrated. Use bolts that are about 20 mm longer than the bolts that were removed.


22. Remove the lower bolts (A) holding the gearbox to the engine.


23. Pull out and let down the gearbox.

Important

The jack can tip over. Be careful.


24. Lift the transmission down from the column jack with an engine lift and 87 92 442 Lifting cable while undoing the lifting tool from the transmission.

25. Plug the holes for the drive shafts if the gearbox is being transported or washed. Use 87 92 665 Protective plug, drive shaft hole , drive shaft hole.


To fit


1. Move over the wire bracket and lower engine mounting.

Tightening torque nuts 22 Nm (16 lbf ft)

Tightening torque, bolts 70 Nm +45° (52 lbf ft +45°)

2. Make sure the two guide sleeves are on the engine and apply grease to the sleeves. Lubricate the primary shaft

3. Fit new drive shaft seal (does not apply to new gearboxes) lubricate it before assembly. Use 87 92 657 Fitting drift, drive shaft seals .

The seal to the right-hand drive shaft sits in the transfer case, replace the O-ring (A) if necessary.


4. Fit 87 92 608 Holder for single-column lift onto a column jack.

5. Secure the tool to the transmission as for removal.

Important

The jack can tip over. Be careful.


Important

Slide in the gearbox until approx. 20 mm are remaining and remove the tool 83 95 162.


6. Fit the gearbox to the engine. Tighten the lower bolts between the engine and the gearbox in the sequence illustrated.

Tightening torque, M10 bolts 40 Nm (30 lbf ft)

Tightening torque, M12 bolts 70 Nm (52 lbf ft)


7. Remove the lifting tool from the gearbox and move away the jack.

8. Fit 83 95 162 Protective collar, drive shafts (A) in the sealing ring. Lubricate the sealing ring. This is done to protect the seal while the transmission is being fitted.


9. Make sure that the drive shaft (B) is clean and then align it with the tool (A).

Important

Fit the drive shaft in the gearbox until approx.20 mm are remaining and pull out the tool before the sealing surface of the shaft reaches the shaft seal.


10. Push in the rest of the shaft (B) until the circlip clicks in.

11. Lower the car to the floor.

12. Fit the upper bolts (A) between the engine and the gearbox.

Tightening torque, M10 bolts 40 Nm (30 lbf ft)

Tightening torque, M12 bolts 70 Nm (52 lbf ft)


13. Lift up the unit and fit the bracket on the engine mounting as marked earlier.

Tightening torque 70 Nm +45° (52 lbf ft +45°)


14. Remove the lifting beam and the holder.

15. Put the wiring harness in place and fit the cable duct (A) to the gearbox. Illustration as with removal.


16. Fit the quick-release coupling to the clutch slave cylinder. Remove the hose pinch-off pliers. Make sure the connection is secured in the correct position. Bleed the clutch. See Bleeding the clutch hydraulic system in the car .

17. Fit the connector for the reversing light switch (B).


18. Fit the cables to the cable retainers by pulling back on the locking sleeves.

19. Fit the gear cables (A) to the gear selector arms.

20. Fit the lower heat shield (B) from the catalytic converter.


21. Fit the upper heat shield (A) over the catalytic converter.

22. Fit the expansion tank (A).


23. Raise the car.

24. Attach the turbo delivery hose (A) to the turbocharger.


25. Fit the Transfer case n.

26. Fit Battery cover, lower section, B284 .

27. Fit the upper engine cover.

28. Perform Adjusting gear cables .

29. Carry out Measures after disconnecting the battery .

30. Remove the wing covers.

31. Test drive the car. Check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed.


PRE-RELEASE