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Complete gearbox, B207 4WD

Complete gearbox, B207 4WD

To remove


1. Place covers over the wings to keep the paintwork clean and protect it from damage.

2. Remove the upper engine cover.

3. Remove the battery cover.

4. Disconnect the battery terminals and remove the battery with cooling pipe.

5. Undo the cable clamp under the battery tray.

6. Disconnect the bonnet switch.

7. Remove the battery tray (A).


8. Lift up the cables (A) from the levers.


9. Remove the gear cables from the gearbox by pulling back on the locking sleeves (B).

10. Fit 30 07 739 Hose pinch-off pliers (A) to the clutch hose and undo the quick-release coupling (B) from the clutch slave cylinder.


11. Remove the upper bolts from the gearbox (A).


12. Lift off the expansion tank from its holder and fit 83 96 178 Lifting eyes, B207 (A) onto the engine.



13. Fit 83 94 850 Lifting beam with 83 95 287 Holder . Replace the holder's lifting hooks. Unload the engine and gearbox.


14. Remove Transfer case, B207 .

15. Lower the car and mark the location of the bolts on the left engine mounting with a marker pen to ensure correct refitting and then remove the screws (A) from the mounting.


16. 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.

17. Raise the car.

18. When replacing the gearbox, remove the front torque rod bracket from the gearbox.

19. Remove the lower gearbox bolts (A). Leave one bolt in place.


20. Detach the ABS cable from the clip using a screwdriver and undo the left-hand drive shaft (A) using 87 92 616 Removal tool, drive shafts .


21. Hang up the shaft with one 83 95 212 Strap .

22. Fit 87 92 608 Holder for single-column lift on a column jack. Adjust and fasten the tool in the gearbox as illustrated.


23. Remove the last bolt, pull out the transmission and lower it.

Important

The jack can tip over. Be careful.


24. 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.

25. Plug the holes for the drive shafts with 87 92 665 Protective plug, drive shaft hole if the gearbox is to be transported any distance.


To fit


1. When replacing the gearbox, transfer the cable bracket and engine mounting.

Tightening torque nuts 22 Nm (16 lbf ft)

Tightening torque, bolts 70 Nm +45° (52 lbf ft +45°)

2. If necessary, perform the procedure Bleeding the slave cylinder .

3. Lubricate the primary shaft splines, see List of lubricants and sealants.

4. Lubricate the guide sleeves on the engine with anti-corrosion agent.

5. Fit a new drive shaft seal, (does not apply to new gearbox) lubricate it before fitting. Use 87 92 657 Fitting drift, drive shaft seals .

6. Fit the gearbox with the lifting tool on the column jack.

Important

Make sure the gear cables are positioned correctly when lifting the gearbox.


7. Fit the rest of the gearbox. Turn the crankshaft if necessary to get the gearbox in place.

Important

The jack can tip over. Be careful.


8. Fit the lower bolts between engine and gearbox in the sequence illustrated.

Tightening torque, M10 bolts 40 Nm (30 lbf ft)

Tightening torque, M12 bolts 70 Nm (52 lbf ft)


9. Remove the lifting tool from the gearbox and move away the jack.

10. Lower the car. Lift in place the power train with the lifting beam until it meets the engine mounting.

11. Fit the bracket (A) for the engine mounting according to the marks made earlier.

Tightening torque 70 Nm +45° (52 lbf ft +45°)


12. Remove the holder, lifting beam and lifting eyes.

13. Fit the coolant reservoir.

14. Fit the upper bolts from the gearbox (A).

Tightening torque 70 Nm (52 lbf ft)


15. 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 .


16. Plug in the reversing light switch.

17. Fit the cables to the cable retainers by pulling back on the locking sleeves (B).


18. Fit the gear cables (A) to the gear selector arms.

19. Raise the car.

20. Fit 83 95 162 Protective collar, drive shafts (A) in the sealing ring. Lubricate the sealing ring. This is to protect the seal when the drive shaft is fitted.


21. Make sure that the drive shaft (B) is clean and then align it with the tool (A).

Important

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.


22. Push in the rest of the drive shaft into the gearbox until the circlip clicks in.

23. Attach the ABS cable to the clip.

24. Fit the front torque rod bracket to the gearbox.

Tightening torque 80 Nm (59 lbf ft)

25. Fit Transfer case, B207 .

26. Check the gear positions and adjust if necessary as described under Adjusting gear cables 6-speed.

27. Fit the battery tray (A) and the bonnet switch connector.


28. Fit the cooling pipe and the battery.

29. Fit the battery cover.

30. Fit the upper engine cover.

31. Remove the wing covers.

32. Carry out Measures after disconnecting the battery .

33. Test drive the car. Check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed.