Complete gearbox, B207 4WD
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Complete gearbox, B207 4WD
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1.
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Place covers over the wings to keep the paintwork clean and protect it from damage.
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2.
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Remove the upper engine cover.
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3.
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Remove the battery cover.
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4.
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Disconnect the cable terminals on the battery and remove the battery with cooling pipe.
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5.
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Undo the cable clamp under the battery tray.
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6.
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Disconnect the bonnet switch.
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7.
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Remove the battery tray (A).
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8.
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Lift up the cables (A) from the levers.
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9.
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Remove the gear cables from the gearbox by pulling the locking sleeves (B) back.
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11.
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Remove the upper bolts from the gearbox (A).
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13.
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Fit 83 94 850 Lifting beam with 83 95 287 Holder. Change positions on the holder's lifting hooks. Take the weight off the engine and gearbox.
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15.
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Lower the car and mark the positions of the bolts on the left-hand engine bracket with a marker pen for correct refitting and then remove the bolts (A) from the mounting.
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16.
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Lower the drive unit approx. 70 mm from the lifting beam to facilitate the removal of the gearbox. Measure the distance at the left-hand engine mounting.
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18.
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When replacing the gearbox, remove the front torque rod bracket from the gearbox.
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19.
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Remove the lower gearbox bolts (A). Leave one bolt in place.
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23.
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Remove the last bolt, pull out the transmission and lower it.
Important
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The jack can tip over. Be careful.
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24.
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Lift the transmission down from the column jack with an engine lift and
87 92 442 Lifting cable
while undoing the lifting tool from the transmission.
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1.
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When replacing the gearbox, move over the wire bracket and engine mounting.
Tightening torque nuts 22 Nm (16 lbf ft)
Tightening torque, bolts 70 Nm +45° (52 lbf ft +45°)
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3.
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Lubricate the primary shaft splines, see List of lubricants and sealants.
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4.
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Lubricate the guide sleeves on the engine with anti-corrosion agent.
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6.
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Fit the gearbox with the lifting tool on the column jack.
Important
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Make sure the gear cables are positioned correctly when lifting the gearbox.
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7.
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Fit the gearbox. Turn the crankshaft if necessary to get the gearbox in place.
Important
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The jack can tip over. Be careful.
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8.
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Tighten the lower bolts between the engine and the gearbox in the sequence illustrated.
Tightening torque, M10 bolts 40 Nm (30 lbf ft)
Tightening torque, M12 bolts 70 Nm (52 lbf ft)
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9.
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Remove the lifting tool from the gearbox and move away the jack.
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10.
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Lower the car. Lift in place the power train with the lifting beam until it meets the engine mounting.
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11.
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Fit the bracket (A) for the engine mounting according to the marks made earlier.
Tightening torque 70 Nm +45° (52 lbf ft +45°)
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12.
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Remove the holder, lifting beam and lifting eyes.
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13.
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Fit the coolant reservoir.
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14.
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Fit the upper bolts from the gearbox (A).
Tightening torque 70 Nm (52 lbf ft)
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15.
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Fit the quick-release coupling (A) to the clutch slave cylinder. Remove the hose pinch-off pliers (B). Make sure the connection is secured in the correct position. Bleed the clutch. See
Bleeding the clutch hydraulic system in the car
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16.
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Plug in the reversing light switch.
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17.
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Fit the cables to the cable retainers by pulling back on the locking sleeves (B).
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18.
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Fit the gear cables (A) to the gear selector arms.
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21.
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Make sure that the drive shaft (B) is clean and then align it with the tool (A).
Important
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Fit the driver in the gearbox until approx.20 mm are remaining and pull out the tool before the sealing surface of the shaft reaches the shaft seal.
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22.
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Push in the rest of the drive shaft into the gearbox until the circlip clicks in.
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23.
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Attach the ABS cable to the clip.
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24.
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Fit the front torque rod bracket to the gearbox.
Tightening torque 80 Nm (59 lbf ft)
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27.
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Fit the battery tray (A) and the bonnet switch connector.
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28.
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Fit the cooling pipe and the battery.
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29.
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Fit the battery cover.
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30.
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Fit the upper engine cover.
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31.
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Remove the wing covers.
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33.
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Test drive the car. Check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed.
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