Complete gearbox, B207 4WD
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Complete gearbox, B207 4WD
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1.
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Place covers over the wings to keep the paintwork clean and protect it from damage.
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2.
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Remove the upper engine cover.
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3.
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Remove the battery cover.
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4.
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Disconnect the battery terminals and remove the battery with cooling pipe.
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5.
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Undo the cable clamp under the battery tray.
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6.
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Disconnect the bonnet switch.
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7.
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Remove the battery tray (A).
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8.
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Lift up the cables (A) from the levers.
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9.
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Remove the gear cables from the gearbox by pulling back on the locking sleeves (B).
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11.
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Remove the upper bolts from the gearbox (A).
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15.
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Lower the car and mark the location of the bolts on the left engine mounting with a marker pen to ensure correct refitting and then remove the screws (A) from the mounting.
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16.
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Lower the drive unit approx. 70 mm from the lifting beam to facilitate the removal of the gearbox. Measure the distance at the left-hand engine mounting.
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18.
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When replacing the gearbox, remove the front torque rod bracket from the gearbox.
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19.
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Remove the lower gearbox bolts (A). Leave one bolt in place.
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23.
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Remove the last bolt, pull out the transmission and lower it.
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Important
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The jack can tip over. Be careful.
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24.
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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.
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1.
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When replacing the gearbox, transfer the cable bracket and engine mounting.
Tightening torque nuts 22 Nm (16 lbf ft)
Tightening torque, bolts 70 Nm +45° (52 lbf ft +45°)
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3.
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Lubricate the primary shaft splines, see List of lubricants and sealants.
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4.
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Lubricate the guide sleeves on the engine with anti-corrosion agent.
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6.
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Fit the gearbox with the lifting tool on the column jack.
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Important
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Make sure the gear cables are positioned correctly when lifting the gearbox.
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7.
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Fit the rest of the gearbox. Turn the crankshaft if necessary to get the gearbox in place.
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Important
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The jack can tip over. Be careful.
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8.
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Fit the lower bolts between engine and gearbox in the sequence illustrated.
Tightening torque, M10 bolts 40 Nm (30 lbf ft)
Tightening torque, M12 bolts 70 Nm (52 lbf ft)
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9.
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Remove the lifting tool from the gearbox and move away the jack.
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10.
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Lower the car. Lift in place the power train with the lifting beam until it meets the engine mounting.
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11.
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Fit the bracket (A) for the engine mounting according to the marks made earlier.
Tightening torque 70 Nm +45° (52 lbf ft +45°)
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12.
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Remove the holder, lifting beam and lifting eyes.
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13.
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Fit the coolant reservoir.
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14.
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Fit the upper bolts from the gearbox (A).
Tightening torque 70 Nm (52 lbf ft)
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15.
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Fit the quick-release coupling (A) to the clutch slave cylinder. Remove the hose pinch-off pliers (B). Make sure the connection is secured in the correct position. Bleed the clutch. See
Bleeding the clutch hydraulic system in the car
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16.
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Plug in the reversing light switch.
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17.
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Fit the cables to the cable retainers by pulling back on the locking sleeves (B).
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18.
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Fit the gear cables (A) to the gear selector arms.
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21.
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Make sure that the drive shaft (B) is clean and then align it with the tool (A).
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Important
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Fit the driver 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.
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22.
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Push in the rest of the drive shaft into the gearbox until the circlip clicks in.
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23.
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Attach the ABS cable to the clip.
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24.
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Fit the front torque rod bracket to the gearbox.
Tightening torque 80 Nm (59 lbf ft)
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27.
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Fit the battery tray (A) and the bonnet switch connector.
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28.
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Fit the cooling pipe and the battery.
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29.
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Fit the battery cover.
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30.
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Fit the upper engine cover.
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31.
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Remove the wing covers.
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33.
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Test drive the car. Check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed.
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