Manual Transmission and
Differential, Remove and Install
-Vehicles without Catalytic
Converter
If only the transmission is to
be removed, e.g. for the 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).
The illustrations show F 16
manual transmission.
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Remove
Detach
clutch cable from release lever.
Beforehand, remove retaining clamp from cable.
Pull
off lead from reversing lamp switch.
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Loosen
bolt for fastening shift rod clamp.
Unscrew
speedometer cable from main case.
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Unscrew
3 screws for main case from upper engine block.
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Suspend
engine from shackle with commercially available spring safety hook using
Engine Lifter KM-263-A without cable.
On
12 SC engine, suspend from cable.
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Raise
vehicle and remove both front wheels.
Unscrew
ground strap from end shield.
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 20 E engines)
Drive
both axle shafts from main case using KM-460-2-A (L.H. shaft, altered tool)
and KM-460-1 (R.H. shaft).
Important:
Bevelled side of tool always points towards transmission.
Use a 1500 gram / 3 ½ lb hammer.
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F
16 Manual Transmission (only 18 E
and 20 E engines)
Drive
L.H. axle shaft from main case using KM-503-A.
Press
R.H. axle shaft out of main case using mounting iron.
Important:
Fluid escapes. Therefore, immediately seal both openings for axle shafts
against oil and dirt, using plugs (available from P & A Department).
Immediately suspend axle shafts, do not allow them
to sag.
Note: If,
in exceptional cases, axle shaft catches during dismantling and cannot be
driven out of main case, it should be driven out using a flat chisel placed
between shaft end and bevel gear shaft.
To do this, remove cover for differential (fluid
will escape).
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All
Manual Transmissions (5-speed manual transmissions up to MY 88 ½)
Pull
out turbine shaft from transmission end shield. To do this, remove screw
cover from end shield.
Remove
fillister head screw from transmission turbine shaft.
Beforehand, remove snap ring.
Mark installation position of transmission turbine
shaft in gear cluster with paint.
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Pull
out turbine shaft as far as stop using KM-556-1-A (previously KM-449-1 in
conjunction with Kukko Counterstay 22-1).
The
longitudinal splines for the clutch disc become free.
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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 circlip 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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All
Manual Transmissions
Remove
front left engine mounting completely.
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Unbolt
rear engine mounting (damper block) from underbody.
In
addition, unbolt exhaust pipe bracket.
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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.
On
F 16/5-speed transmission, slightly loosen two bolts on transmission switch.
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Important:
If the complete transmission
with differential is not to be subsequently overhauled and is therefore not to
be fastened to the trans- mission support, the unit should be carefully stored.
The assembly may not rest on the transmission turbine shaft ends, 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 - 75 Nm/55.32 lbf. ft. or 65 Nm/47.94
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).
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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.
5-speed
Manual Transmission (up to MY 88 ½)
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 0037 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.
Use 3 spacer sleeves on 4-speed manual transmission
(illus. B 8231).
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 - tighten to 50 Nm/36.88 lbf. ft.
After cap has been screwed tight, 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 to end shield.
Tighten
wheel bolts, alternating crosswise - 90 Nm/66.38 lbf. ft.
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5-speed
Manual Transmission (as of MY 88 ½)
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 1.25 = 20 Nm/14.75 lbf. ft.
Screw
ground strap onto end shield.
Tighten
wheel bolts, alternating crosswise: 90 Nm/66.38 lbf. ft.
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Install lead for reversing
lamp switch, speedometer cable and clutch cable.
Secure lead with retaining clip.
Adjust transmission shift
linkage (see operation in this group).
Check transmission fluid
level and top up.
Fluid is filled through
opening for bleeder screw plug.
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 (illus. C 0038)
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