To remove, gearbox, 4-cyl. diesel
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To remove, gearbox, 4-cyl. diesel
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Warning
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Cables, hoses, leads etc. are secured with hard plastic cable ties. After being tightened, the ends are cut off, leaving sharp edges at the fixing points. Be aware of the risk of injury due to these sharp ends of cable ties.
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1.
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Place the car on a lift.
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2.
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Cover the wings to avoid paintwork damage and soiling.
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3.
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Remove the upper engine cover.
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4.
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Remove the plastic cover from the battery. Detach the battery leads from the battery.
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5.
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Remove the battery. Remove the MAXI fuse board and place it to one side. Remove the battery tray.
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6.
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Undo the cable tie, detach the main fuse board and move it aside.
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8.
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Remove the clip that secures the selector rod in the linkage on the gearbox.
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9.
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Lift up the gaiter. Engage 3rd gear so that the selector rod disengages from the linkage and fit
87 92 335 Locking pin
in the selector lever housing.
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10.
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Prevent brake fluid from escaping from the brake fluid reservoir by sealing the brake fluid hose with
30 07 739 Pinch-off pliers
.
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11.
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Remove the clip by the slave cylinder and disconnect the connection for the delivery line. Refit the clip.
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12.
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Unplug the reversing light switch.
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13.
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Remove the 3 upper bolts securing the gearbox and stay.
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14.
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Disconnect the selector linkage by the gearbox.
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15.
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Remove the nut from the rear engine mounting. Undo the 3 bolts securing the rear engine mounting. Use a long 10 mm socket, an extension piece with ball (e.g. 30 17 613) and
82 93 102 Extension, 500 mm, 3/8 square
. Leave the bolts in place.
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16.
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Remove bolts securing the front exhaust pipe.
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17.
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Slightly lift the engine and gearbox with
83 94 850 Lifting beam
. Position the beam so that it rests on the edges of the wings near the wing retaining bolts.
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18.
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Raise the car. Remove the front wheels.
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19.
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Remove the two lower engine covers and the two side covers from the wheel housing.
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20.
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Remove the headlamp levelling sensors (option) and move it aside.
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21.
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Remove the front exhaust pipe and catalytic converter.
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22.
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Remove the bolt securing the front torque rod to the subframe.
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23.
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Remove the clips that secure the steering servo delivery line.
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24.
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Remove the nuts securing the steering servo coolant pipe.
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25.
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Detach the air cleaner from the subframe.
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26.
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Remove the A/C lines from the plastic clips on the subframe.
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27.
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Place a
83 95 212 Strap
around the radiator and radiator crossmember to suspend the radiator.
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28.
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Remove the bolts that secure the outer ball joints to the steering swivel member on both sides.
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29.
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Remove the upper ball joint, on both sides, from the anti-roll bar. Offer resistance with an open 17 mm wrench so that the gaiter does not twist. If the wrench is too wide to be inserted between the gaiter and MacPherson strut, grind it down.
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30.
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Remove the 4 bolts that secure the rear support plates and the 2 rearmost bolts for the subframe.
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32.
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Remove the remaining 4 bolts securing the subframe.
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34.
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Lower the subframe slightly and detach the steering gear.
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35.
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Remove the suspension arm from the steering swivel member, lower the lifting trolley and subframe slightly more and move them aside.
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36.
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Undo the gearbox level plug and drain plug. Drain the gearbox oil. Refit the drain plug.
Tightening torque 50 Nm (37 lbf ft)
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37.
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Remove the rear engine mounting and engine pad.
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38.
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Remove the rear bolts securing the gearbox.
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40.
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Remove the two grounding cables from the gearbox.
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41.
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Lower the car. Remove the bolts and nut from the left-hand engine mounting and remove it.
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42.
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Lower the engine so that the gearbox clears the structural member. Remove the gearbox mounting from the gearbox.
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43.
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Raise the car. Fit
87 92 608 Holder for single-column lift
to a single-column jack. Connect the lifting tool to the gearbox, adjust the lifting tool so its centre is aligned with the centre of the gearbox and mounting face.
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44.
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Remove the remaining between the engine and gearbox. Pull out and lower the gearbox.
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Warning
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Be careful that the jack does not tip over.
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45.
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Lift the gearbox from the jack and remove the lifting tool from the gearbox.
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