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Manual Transmission, Remove and Install (Vehicles
with V6 Engine)
 Remove
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Disconnect battery. Completely fill brake fluid reservoir and
seal with dummy screw cap. Open retaining strap (2) for connection
piece at bulkhead. Remove retaining clamp (1) and disconnect clutch
actuation pressure line. Reinsert retaining clamp (1).
Caution
Collect escaping brake fluid.
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Note: For vehicles
with Y 26 SE engine, two oxygen sensor wiring harness plugs each on
left and right side must additionally be disconnected.
Remove
Raise vehicle.
Cut off cable tie at transmission. Unclip both wiring harness
plugs (2) of oxygen sensors from bracket. Lift retaining brackets
(1) and disconnect wiring harness plug. Lift retaining bracket and
disconnect wiring harness plug from reversing lamp switch.
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Disconnect front exhaust pipes between catalytic converter and
front muffler (arrows). Unscrew front exhaust pipes from exhaust
manifold and bracket and remove. Release pressure line of clutch
actuation downwards.
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Unscrew propshaft from transmission flange. Push propshaft
together and suspend on one side.
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Remove 4 clips of shift outrigger cover. Push cover
forwards.
Remove retaining clamp from pin. Pull pin out of shift rod and
fork. Unscrew shift outrigger from transmission and secure against
tipping with tyre lever.
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Support transmission with hydraulic jack. Unscrew crossmember
from underbody (arrows).
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Unscrew 4 lower screws (Torx bit E 12, 1) from engine block.
Unscrew 4 upper screws on transmission side from engine block.
Unscrew 2 upper screws (arrows) on engine side from
transmission.
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Lower transmission with hydraulic jack, so that it can be moved
past the shift outrigger. Press transmission off engine block and
lower.
Install
Engage one gear at the outer shift rod. Thinly coat teeth of
transmission drive shaft with lubricating paste. Raise transmission
with hydraulic jack and insert transmission drive shaft in clutch
plate. Align transmission so that the guide sleeves align with the
corresponding borings in the transmission.
Torque
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Install 4 upper screws on transmission side in engine block
– 60 Nm / 44 lbf. ft.
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Install 2 upper screws (arrows) on engine side in transmission
– 60 Nm / 44 lbf. ft.
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Install 4 lower screws (Torx bit E 12, 1) in engine block
– 60 Nm / 44 lbf. ft.
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Torque
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Bolt transmission crossmember at vehicle floor (arrows) –
45 Nm. Cut thread and insert fastening bolts with locking
compound.
Lower hydraulic jack.
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Remove tyre lever from shift outrigger.
Torque
Install shift outrigger to transmission (arrows) – 20 Nm /
15 lbf. ft.
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Install
Insert pin in shift rod and fork. Secure pin with retaining
clamp. Fasten cover for shift rod with 4 clips.
Torque
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Install propshaft to transmission flange – 95 Nm / 70 lbf.
ft.
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Attach front exhaust pipes between catalytic converter and front
muffler – 25 Nm / 18 lbf. ft.
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Attach front exhaust pipes with new gaskets to exhaust manifold
– 30 Nm / 22 lbf. ft.
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Bolt front exhaust pipes to bracket – 20 Nm / 15 lbf.
ft.
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Install
Connect wiring harness plugs of oxygen sensors, so that
retaining bracket snaps in. Snap in wiring harness plug in
transmission bracket. Connect wiring harness plug to reverse lamp
switch, so that retaining bracket snaps in. Lower vehicle.
Guide pressure line for clutch actuation upwards. Insert
pressure line into connection piece, pressure line must engage
audibly in retaining clip. Fasten connection piece with retaining
strap to bulkhead.
Unscrew dummy screw cap from brake fluid reservoir. Bleed clutch
actuation – see operation "Hydraulic Clutch Actuation,
Bleed". Connect battery. Install transmission cover if
available.
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