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Installing gearbox
Installing gearbox
Installation is carried out in reverse sequence; note the following:
  Note
t  Renew self-locking nuts and bolts when performing assembly work.
t  Renew oil seals and gaskets, and bolts which are tightened by turning through a specified angle.
t  Secure all hose connections with the correct hose clips (as original equipment); refer to → Parts catalogue.
t  All cable ties which are released or cut open during removal must be fitted in the same position when installing.
–  Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease for clutch plate splines -G 000 100- to the splines. It is important to remove excess grease.
l  It should be possible to push the clutch plate back and forth slightly on the input shaft.
–  Check that dowel sleeves for centralising engine/gearbox are in the cylinder block; install if necessary.
–  Check clutch release bearing with hydraulic actuator for wear and renew if necessary.
   
–  Engage intermediate plate at sealing flange and push onto dowel sleeves -arrows-.
  A10-0129
–  Tilt gearbox to the left by turning spindles of gearbox support -3282-.
–  Raise gearbox carefully and move to installation position using gearbox support.
  N34-1293
–  Push the gearbox over the engine flywheel at the front first -arrow- and then at the bevel box side.
–  Install gearbox.
Vehicles with bevel box bracket (metal casting):
–  Install bevel box bracket prior to fitting engine/gearbox securing bolts.
  A34-0257
Continued for all vehicles:
–  Fit new engine/gearbox securing bolts which are accessible from below. Tightening torques → Anchor
  A37-0214
Vehicles with bevel box bracket (metal casting):
–  Screw in bevel box bracket bolts -A ... C- only a few turns at this stage.
  N34-1067
–  Observe the further tightening sequence:
1.  First tighten bolts -A- to 3 Nm.
2.  Tighten bolts -B- and -C- to 35 Nm.
3.  Tighten bolts -A- to 45 Nm.

   
Vehicles with bevel box bracket (sheet metal version):
–  Screw in bevel box bracket bolts -A ... C- only a few turns at this stage.
  N34-1471
–  Observe the further tightening sequence:
1.  First tighten bolts -A- to 3 Nm.
2.  Tighten bolts -B- to 35 Nm.
3.  Tighten bolt -C- to 22 Nm.
4.  Tighten bolts -A- to 45 Nm.

–  Detach gearbox support -3282- from gearbox.
   
–  If fitted, install small flywheel cover plate -A- at rear of bevel box and secure bolt -arrow-.
–  Fit new engine/gearbox securing bolts which are accessible from above.
  N34-1121
Engine/gearbox securing bolts
  A37-0214
ItemBoltNm
1, 2 1)M12x5580 2)
3 1), 4 1)M12x16580 2)
5M10x10540 2)
6, 7M10x5040 2)
8M12x7080 2)
ADowel sleeves for centralising
l  1) Bolt with stud M8
l  2) Renew bolts

   
–  Use new bolts -1- to secure gearbox support to gearbox.
–  Pull gearbox up to gearbox support with spindle on support bracket.
  Caution
Before screwing in the bolts, the support arm of the gearbox mounting and the gearbox support must be aligned absolutely parallel, otherwise the threads will be damaged. If necessary, push gearbox up at the rear with trolley jack.
–  Use new bolts -2- to secure support arm of gearbox mounting to gearbox support.
  WARNING
Support bracket -10-222 A- must not be removed until all bolts on left and right assembly mountings have been tightened to specified torque.
–  Remove support bracket.
–  Install subframe as follows:
–  Move drive shafts into installation position and tighten hand-tight.
–  Move subframe into installation position.
–  Fit subframe bolts.
  A34-0231
–  Place steering box onto subframe and fit steering box bolts.
l  Threaded sleeve -1- must be positioned in hole in subframe
l  Rubber buffer on opposite side must be positioned on corresponding projection on subframe.
–  Secure steering box → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.48.
  N48-0284
–  Use new bolts to secure subframe -1- → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.48.
–  Where fitted, secure cross piece -3- using new bolts and locking fluid -D 000 600 A2- to subframe -1-.
Installation position: Marking “L” or “links” (left-side) must be positioned on the left as seen in direction of travel. Foam strip faces downwards -arrow-.
–  Bolt drive shafts to gearbox flange shafts → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40.
  A40-0271
–  Install heat shield for drive shaft (right-side) -arrows-.
  A10-10260
–  Secure pendulum support to gearbox with new bolts -arrows B-.
–  Press engine/gearbox assembly towards bulkhead; the bevel box pin must be guided carefully into the propshaft flange when doing this.
  A10-0928
–  Slide propshaft onto guide pin without tilting.
  Caution
Make sure that the seal -arrow- in the flange of the propshaft is not damaged when removing and installing. If seals are damaged, the propshaft must be renewed.
  V39-1817
–  Secure pendulum support to subframe with new bolts -arrows A-.
  N34-0887
–  Bolt propshaft to flexible coupling on bevel box flange -arrows-: → Rear final drive 02D; Rep. Gr.39.
–  Install exhaust system free of stress → Rep. Gr.26.
  A39-0289
–  Press pressure pipe -1- into hose connector and lock in position with retaining clip.
  Caution
Do not press clutch pedal before clutch system has been bled.
–  Remove hose clamp -3094-.
–  Attach electrical connector for reversing light switch -F4--2-.
–  Install starter and fit bottom bolt. Tightening torques → Anchor
  A34-0240
–  Fit power steering pipe to gearbox -arrows-.
  A34-0246
–  Fit pressure pipe -2- to power steering pump with new seals → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.48.
–  Remove hose clamps -3094-.
–  Attach electrical connector -1- for power steering pressure switch.
Vehicles with two charge air coolers:
–  Fit power steering pump pulley and poly V-belt pulley → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.48.
–  Install tubular cross member → General body repairs, exterior; Rep. Gr.50.
Continued for all vehicles:
–  Check gear oil in manual gearbox with bevel box → Chapter.
–  Install noise insulation panels → General body repairs, exterior; Rep. Gr.50.
Vehicles with one charge air cooler:
–  Attach air pipe leading to charge air cooler at longitudinal member (bottom right).
Continued for all vehicles:
–  Install top bolt securing starter. Tightening torque → Anchor.
  A34-0245
–  Attach electrical connector -3-.
–  Fit bracket -2-, attach wiring and engage connector in bracket.
–  Fit earth wire -1-.
  A37-0195
–  Fit selector shaft lever -B- with gear selector cable on selector shaft (tighten nut -arrow 3-).
–  Install relay lever -A- with gate selector cable (insert securing clip -arrow 2-).
–  Tighten nut -arrow 1-.
  N34-1304
–  Attach cable support bracket to gearbox -arrows-.
  N34-1039
–  Plug in electrical connector at speedometer sender -G22--arrow-.
–  Make sure that mountings of engine/gearbox assembly are free of tension when installing → Rep. Gr.10.
–  Bleed clutch system → Chapter.
–  Adjust selector mechanism → Chapter.
–  Install battery tray.
–  Install air cleaner housing.
–  Install battery; follow steps required after connecting battery → Electrical system; Rep. Gr.27.
–  Attach engine cover panel.
Tightening torques
  A10-0924
ComponentNm
Flywheel cover plate to gearbox10
Gearbox support to gearbox40 + 90° 1) 2)
Gearbox console to gearbox mounting60 + 90° 1) 2)
Pendulum support togearbox40 + 90° 1) 2)
 subframe20 + 90° 1) 2)
Cross piece to subframe (if fitted)30 + 90° 1) 2) 4)
Heat shield to gearbox25
Heat shield to gearbox25
Flywheel cover plate to gearbox10
Pressure pipe of power steering to gearbox support22
Selector cable support bracket to gearbox23
Selector shaft lever to selector shaft20 3)
Air cleaner housing to body10
Air pipe to longitudinal member10
l  1) Renew bolts
l  2) 90° = one quarter turn
l  3) Renew nut
l  4) Apply locking fluid -D 000 600 A2- when fitting

   

Power transmission > 5/6-speed manual gearbox 02M/02Y, four-wheel drive > Gearbox mechanics,operation, construction,diff. > Removing gearbox > Installing gearbox

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