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Gearbox, removal and fitting

Gearbox, removal and fitting

To remove


1. Place covers on the wings to protect the paintwork from damage and dirt and remove the upper engine cover.


2. Remove the battery cover.

3. Disconnect the battery terminals and remove the battery.

4. Undo the cable clamp under the battery tray.

5. Unplug the bonnet switch connector.

6. Remove the battery tray.


7. Undo the ground cable from the engine mounting


8. Undo the delivery line from the gearbox

Seal off the brake fluid reservoir with 30 07 739 Hose pinch-off pliers .

Pull free the locking clip (5) and pull out the delivery line (6) from the central clutch connector plug (4)

Slightly squeeze together the locking clip put it in the connector plug

9. Remove the clutch cables from the gearbox

Bend the gear selector cables (2) free from the gear change lever with KM-6042

2x Free from the support

Note: Retract the sleeve (1) and pull out the cable from the support

10. Free the gearbox at the top

3x Undo the upper bolts (arrowed)

Note: Unscrew the rearward bolt first, so that the coolant hose can be lifted slightly


11. Remove the selector cable supports

2x Unscrew bolts (2)

Remove the support (1)


12. Fit 83 94 850 Lifting beam (Follow the directions of manufacturer)

Support the radiator with two straps 83 95 212 Strap

13. Remove the exhaust system

14. Put in place 83 96 145 Centring jig, subframe - engine with 83 96 368 Supplementary set for centring jig (1) in the front subframe

Note: In order to ensure that the drive train is correctly adjusted when the engine mount bolts, LH and RH, have been loosened, the drive train must be positioned relative to the front subframe with 83 96 145 Centring jig, subframe - engine

Put in place 83 96 145 Centring jig, subframe - engine .

The pins (3, 6) must be located in the guide holes in the front subframe

2x Tighten the adjustment rail bolts (arrowed)

Screw up the rear support bearing (4) until it locates in the guide pin on the rear engine mount holder without any free-play

Screw up the front support bearing (5) until it locates in the guide pin on the rear engine mount holder without any free-play



15. Remove the front subframe

Important 83 96 145 Centring jig, subframe - engine remains attached to the subframe and must not be adjusted

see Help frame, removal and fitting, Z18XE

16. Remove the LH engine mount

3x Unscrew bolts (1)

Important: Check that the engine and engine components are not resting against the front suspension frame or subframe. Cables and hoses must not be stretched.

17. Lower the engine/gearbox

Lower using lifting beam 83 94 850 Lifting beam , until the gearbox is not up against the subframe whilst removing


18. Remove the front engine mount (1)

2x Unscrew bolts (2)

19. Remove the rear engine mount (4)

3x Unscrew the rear bolts (3)

20. Remove the LH drive shaft

Note: Put an oil tray underneath as oil will run out

Note: The drive shaft remains attached to the wheel hub

Tie up the drive shaft to the underside of the car.

Put in a plug

21. Remove the RH drive shaft

Note: Put an oil tray underneath as oil will run out

Note: The drive shaft remains attached to the wheel hub

Tie up the drive shaft to the underside of the car.

Put in a plug

22. Detach the gearbox from the oil pan

3x Unscrew bolts (1)

Important: Follow the directions of the manufacturer 87 92 608 Holder for single-column lift .


23. Fit the gearbox holder 87 92 608 Holder for single-column lift (1)

Connect to the hydraulic lift and the gearbox


24. Detach the gearbox from the engine

3x Undo the bolts (arrowed)

Free the gearbox from the engine

Carefully lower the gearbox with 87 92 608 Holder for single-column lift - pay attention to wiring and other connections

25. Fit the gearbox to the engine

Note: Smear a little lubricating grease on the drive shaft teeth before mounting the gearbox on the engine

Important: Follow the manufacturer's directions carefully

Carefully lift up the gearbox with the hydraulic lift

Important: Check that no cables and holders are squeezed in between the engine and gearbox

Adjust the gearbox and locate it evenly on the engine

3x Tighten the bolts (arrowed) (60 Nm)


26. Remove the gearbox holder

Remove the gearbox holder 87 92 608 Holder for single-column lift (1) from the hydraulic lift and the gearbox

27. Fit the gearbox to the oil pan

3x Tighten the bolts (40 Nm)


28. Fit the LH engine mount on the gearbox

Note: Raise the engine/gearbox into position with 83 94 850 lifting beam . Check that there is some free play between the LH engine mount and the engine mount holder.

3x Screw the bolts into position but do not tighten as the engine/gearbox must be adjusted in relation to the front suspension frame.


29. Fit the gear selector cable support (1)

Fit to the support

3x Screw in the upper bolts on the gearbox but do not tighten yet.

2x Tighten the bolts (2) (20 Nm)


30. Fit the gearbox to the engine

3x Tighten the upper bolts (arrowed) (60 Nm)

Note: Fit the longer bolt together with the coolant hose


31. Fit the RH drive shaft

Put an oil tray underneath as oil will run out

Remove the plug

32. Fit the LH drive shaft

Put an oil tray underneath as oil will run out

Remove the plug


33. Fit the front engine mount on the gearbox

2x Tighten the bolts (80 Nm)

34. Fit the rear engine mount holder to the gearbox

3x Tighten the bolts (80 Nm)

35. Fit the subframe

Note: In order to ensure that the drive train is correctly adjusted when the engine mount bolts, LH and RH, have been loosened, the drive train must be positioned relative to the front subframe with 83 96 145 Centring jig, subframe - engine .

see the service procedure "Front suspension beam, removing and fitting"

Note: Check that the guide pins of the rear engine mount holder and the front engine mount are located in the support bearings (2, 3) on 83 96 145 Centring jig, subframe engine (1). The support bearing must not be adjusted.


36. Remove 83 96 145 Centring jig, subframe - engine

Lower the engine/gearbox with 83 94 850 Lifting beam

Note: The guide pin for the front engine mount and the rear engine mount holder must be located in the support bearing on 83 96 145 Centring jig, subframe - engine

Remove the lifting beam

37. Fit the LH engine mount

Tighten the three LH engine mount bolts (1) (55 Nm)


38. Fit the rear engine mount

Tighten the engine mount holder (80 Nm)

39. Fit the front engine mount

Tighten the front suspension frame fixing using a new nut (80 Nm)

40. Remove 83 96 145 Centring jig, subframe - engine .


41. Fit the exhaust system

42. "Gearbox oil level, checking and adjusting"

see service procedure Gearbox oil level, checking and correcting F17 .


43. Assemble the gear selector cables to the gearbox

2x Fit into the support

Note: Retract the sleeve (1) and fasten the cable into the support

Attach the gear selector cables (2) to the gear cover

44. Re-connect the reversing light switch to the wiring loom

Replace the wiring loom connector (3)

45. Fit the delivery line (5)

Fit the central clutch delivery line connector plug (4)

Caution: It must be securely snapped into place

46. Hydraulic system, bleeding

see Bleeding the clutch hydraulic system .


47. Attach the ground cable to the engine mounting.

Tightening torque 18 Nm (13 lbf ft)

48. Fit the battery tray and the bonnet switch connector.

49. Fit the battery.

50. Fit the battery cover and upper engine cover.

51. Remove the wing covers.

52. Carry out Measures after disconnecting the battery .