Manual
Transmission and Differential, Remove and Install -Vehicles With Catalytic
Converter
If
only the manual transmission is to be removed, e.g. for operations
"Transmission, Overhaul" or "Synchronizer Rings,
Replace", the transmission end shield together with the main shaft and
turbine shaft should be removed from the main case (see operation "Synchronizer
Rings, Replace" in this group).
Loosen
bolt for fastening shift rod clamp.
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Remove
Detach
clutch cable from release lever.
BBeforehand remove retaining clamp from cable.
Disconnect
lead for reversing lamp switch.
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Disconnect
cable from odometer frequency sensor.
Unscrew
speedometer cable from main case.
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Unbolt
3 bolts for main case from upper engine block.
Unscrew
and remove retainer for heater hose (not illustrated).
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Suspend
engine from shackle with commercially available safety hook using Engine
Lifter KM-263-A without cable.
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Raise
vehicle, remove both front wheels.
Unscrew
ground strap with interference suppression condensator from main case.
Press
swivel joint on both sides out of steering knuckle using KM-507-C.
F
10 , F 13 and F
16 Manual Transmission (except 18 E and 2.0 litre engines) Drive both
axle shafts from main case using KM-460-2-A (L.H., altered tool) and KM-460-1
(R.H.).
Important:Chamfered side of tool always points towards
transmission.
Use
a 1500 gram / 3 1/2 lb hammer.
Important:Fluid escapes. Therefore, immediately seal both
openings for axle shafts using plugs (available from P & A Department).
Seal
oil-tight and dirt-tight.
Immediately
suspend axle shafts. Do not allow them to sag.
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F 16 and F
20 Manual Transmission (18 E and 2.0 litre engines only) Drive left hand
axle shaft from main case with KM-503-A and right hand axle shaft with
KM-460-2A (Illus. C 7660).
Important:Chamfered side of tool always points towards
transmission.
Use
a 1500 gram / 3 1/2 lb hammer.
Important:Fluid escapes. Therefore, immediately seal both
openings for axle shafts using plugs (available from P & A Department).
Seal
oil-tight and dirt-tight.
Immediately
suspend axle shafts. Do not allow them to sag.
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F
10 , F 13 and F 16 Manual
Transmission (except 5-speed manual transmission as of MY 88 ½)
Pull
out transmission turbine shaft from transmission end shield.
Unscrew
fillister head screw from transmission turbine shaft.
Beforehand, remove snap ring.
Mark installation position of transmission turbine
shaft in relation to gear cluster with paint.
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Pull
out transmission turbine shaft using KM-556-1-A (previously KM-449-1 in
conjunction with Kukko Counterstay 22-1) as far as stop.
Longitidunal
splines for clutch disc become free.
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F
10 , F 13 and F 16 Manual Transmission (except 5-speed manual transmission as of MY 88 ½)
Unbolt
transmission cover from end shield.
Important: Fluid
escapes.
Pull
transmission turbine shaft out of transmission end shield.
Remove
fillister head screw from transmission turbine shaft.
Remove snap ring beforehand.
Mark position of transmission turbine shaft in
relation to gear cluster with paint.
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Pull
out transmission turbine shaft using KM-556-1-A (previously KM-449-1 in
conjunction with Kukko Counterstay 22-1) and Adapter KM-556-4 as far as stop.
Longitidunal
splines for clutch disc become free.
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Remove
front left engine mounting completely.
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Unbolt
rear engine mounting (damper block) from underbody.
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F
20 Manual Transmission
Unbolt
transmission cover from end shield.
Important:Fluid
escapes.
Pull
transmission turbine shaft out of transmission end shield.
Unscrew
cylinder head bolt from transmission turbine shaft.
Beforehand, remove securing ring.
Mark installation position of the transmission
turbine shaft in relation to the gear cluster with paint.
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Pull
out transmission turbine shaft using KM-556-1-A (previously KM-449-1 in
conjunction with Kukko Counterstay 22-1) and Adapter KM-556-4 as far as stop.
Longitidunal
splines for clutch disc become free.
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Remove
front left engine mounting completely.
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Unbolt
exhaust bracket from rear engine mounting.
Unbolt
rear engine mounting (damping block) from underbody.
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All
Transmissions
Unbolt
main case from engine block and cover plate from main case.
Press
main case sideways off engine block and remove.
Use
Transmission Holding Fixture KM-444-B together with hydraulic prop jack.
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Important:
If the
complete manual transmission with differential is not to be subsequenty
overhauled and is therefore not to be fastened to the transmission support, the
unit should be carefully stored. The assembly may not rest on the transmission
turbine shaft end, the shift rod joint the clutch release lever, the screw cap
for bleeding the transmission, the reversing lamp switch or the speedometer
drive.
Store assembly in the same
position in Which it is installed.
Install
Bolt main case to engine block
- 75 Nm/55.32 lbf. ft. Install first rear and then front engine mountings free
of tension - observe prescribed torque.
- rear engine mounting (damper block), to underbody:
75 Nm/55.32 lbf. ft.
- front left engine mounting, to anti-vibration block:
65 Nm/47.94 lbf. ft.
- front left engine mounting, to transmission case: 65
Nm/47.94 lbf. ft.
- front left engine mounting, to side member: 75
Nm/55.32 lbf. ft.
To fasten rear engine mounting (damper block), coat
new bolts (not micro-encapsulated) with Locking Compound 15 10 177 (90
167 347).
Recut both threaded holes to M 10 x 1.25.
First press both axle shafts
into main case. Then drive them in with a screwdriver until snap ring catches.
Position screwdriver on bead of friction weld (not on
metal covering).
After snap ring catches, check for secure seating by
pulling by hand at widest part of joint.
Important:
Secure seating of axle shaft cannot be checked by
pulling shaft itself.
Beforehand, insert new snap ring into stub
groove of joint.
Important:
Do not overstress snap ring.
Beforehand, lubricate axle shaft bearing in
differential housing with Transmission Fluid 19 40 750 (90 001 777).
F
10 , F 13 and F 16 Manual Transmission
(except
5-speed manual transmission as of MY 88 ½)
Attach
swivel joint to corresponding steering knuckle with castellated nut and
secure with retaining clip - important retaining component, tighten to 70
Nm/51.63 lbf. ft.
By
hand carefully insert or slip
transmission turbine shaft into gear teeth of clutch disc and gear cluster
(teeth in longitudinal splines of both shafts must seat in corresponding
tooth gaps of clutch disc and gear cluster).
Illus.
P 0039 shows centering after installation of clutch disc.
Note
paint marks made on transmission turbine shaft and gear cluster during
removal.
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Screw fillister head screw
into transmission drive shaft and press shaft into gear cluster as far as stop
using KM-564. Secure turbine shaft with snap ring.
Use new snap ring.
Insert screw cap oil-tight
into bearing cover with Sealing Compound 15 03 166 (90 094 714 ) or PVC tape -
50 Nm/36.88 lbf. ft. After cap has been screwed in, distance between front of
cover and surface of end shield must not exceed 4 mm/0.157 in., in order to
obtain specified sealing screw depth. Screw ground strap with inference
suppression capacitor to main case. Screw on retainer for heating hose. Tighten
wheel bolts alternating crosswise - 90 Nm/66.38 lbf. ft. Install lead for
reversing lamp switch, speedometer cable and clutch cable.
Secure
bowden cable with retaining clamp.
F
10 , F 13 and F 16 Manual Transmission
(except
5-speed manual transmission as of MY 88 ½)
Attach
swivel joint to corresponding steering knuckle with castellated nut and
secure with retaining clip - important retaining component tighten to 70
Nm/51.63 lbf. ft.
By
hand carefully insert or slip transmission
turbine shaft into gear teeth of clutch disc and gear cluster (teeth in
longitudinal splines of both shafts must seat in corresponding tooth gaps of
clutch disc and gear cluster).
Illus.
C 7656 shows centering after installation of clutch disc.
Observe
paint marks made on transmission turbine shaft and gear cluster during
removal.
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Screw
fillister head screw into transmission turbine shaft and press shaft into
gear cluster as far as stop using KM-564. Secure turbine shaft with snap
ring.
Use new snap ring.
Bolt
transmission cover to end shield.
Prescribed
torque:
M7
x 1.0 = 15 Nm/11.06 ibf. ft.
M8
x 1.2 = 20 Nm/14.75 ibf. ft.
Screw
ground strap with interference suppression capacitor to main case. Screw on
retainer for heating hose. Tighten wheel bolts alternating crosswise - 90
Nm/66.38 lbf. ft. Install lead for reversing lamp switch, speedometer cable
and clutch cable.
Secure
bowden cable with retaining clamp.
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Adjust transmission shift
linkage (see operation in this group).
Check transmission fluid and
top up.
Transmission fluid is filled
through opening for bleeder screw plug in shift cover.
Fluid level = lower edge of
inspection aperture.
Inspection aperture on "F
10" and "F 13" manual transmission, L.H. rear looking in
direction of travel.
Inspection aperture on "F
16" manual transmission, R.H. rear looking in direction of travel.
F
20 Manual Transmission
Attach
swivel joint to corresponding steering knuckle with castellated nut and
secure with retaining clip. Important retaining component tighten to 70
Nm/51.63 lbf. ft.
By
hand carefully insert or slip
transmission turbine shaft into gear teeth of clutch disc and gear cluster
(teeth in longitudinal splines of both shafts must seat in corresponding
tooth gaps of clutch disc and gear cluster).
Illus.
C 7656 shows centering after installation of clutch disc.
Note
paint marks made on transmission turbine shaft and gear cluster during
removal.
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Screw
fillister head screw into transmission turbine shaft and press shaft into
gear cluster as far as stop using KM-564.
Secure
turbine shaft with snap ring.
Use new snap ring.
Bolt
transmission cover to end shield.
Prescribed
torque:
M
7 x 1.0 = 15 Nm/11.06 lbf. ft.
M
8 x 1.2 = 20 Nm/14.75 lbf. ft.
Screw
ground strap with inference suppression capacitor to main case.
Screw
on retainer for heating hose.
Tighten
wheel bolts alternating crosswise - 90 Nm/66.38 lbf. ft.
Install
lead for reversing lamp switch, speedometer cable and clutch cable.
Secure
cable with retaining clip.
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Adjust
transmission shift linkage (see operation in this group).
Check
transmission fluid and top up.
Transmission
fluid is filled through opening for bleeder screw plug in shift cover.
In
order to check the fluid level, construct an ad hoc tool (e.g. out of welding
rod) as in illustration.
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Fluid
level = 5 mm/0.2 in. below inspection aperture Inspection aperture on F 20
manual transmission, R.H. rear looking in direction of travel.
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