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Gearbox removal Z19

Gearbox removal Z19

Warning

Cables, hoses, leads etc. are secured with hard plastic cable ties. After being tightened, the ends are cut off, leaving sharp edges at the fixing points. Be aware of the risk of injury due to these sharp ends of cable ties.



1. Place the car on a lift.

2. Remove the upper rivets and bolts from the bumper shell and place two 83 95 212 Straps over the radiator member to suspend the radiator core later.

3. Fit wing covers to prevent paint damage and soiling of the wings.

4. Remove the upper engine cover with insulation.


5. Cars with battery cover: Lift the cover off of the battery. Alla: Detach the battery cables.

6. Remove the battery. Detach and move aside the maxi fuse holder and remove the battery tray.


7. Disconnect the electrical distribution unit and move it aside.


8. Lock in 4th at the gearbox by removing the plastic plug and inserting 87 92 335 Lock pin .


9. Release the clamp which holds the selector rod in the gearbox linkage.

10. Engage 3rd gear so that the selector rod goes out of the linkage.

11. Detach the gear linkage at the gearbox and engine mounting. Remove the linkage. Keep track of the washer that sits on the selector rod.


12. Remove the upper bolts of the starter motor.


13. Remove the bracket from the coolant pipes and the positive cable clamp.

14. Remove the starter motor connection cables.

15. Remove the upper gearbox bolts.


16. Remove the positive cable clamps from the gearbox.


17. Prevent brake fluid draining from the reservoir by blocking the brake fluid hose using 30 07 739 Hose pinch-off pliers .

18. Remove the locking clip at the slave cylinder and release the connection to the pressure pipe. Refit the locking clip.

19. Remove the nuts on the rear engine mount. Loosen the 3 bolts holding the rear engine mount using a long 10 mm socket, an extension with ball (e.g. 30 17 613) and Extension, 500 mm, 3/8 square 82 93 102. Leave the bolts in place.


20. Remove the connector from the reversing light switch.

21. Relieve the load on the engine and gearbox with 83 94 850 Lifting beam . Place the yoke on the wheelarch so it lies against the wing edges and near the wing fixing bolts.


22. Lift the car. Remove the front wheels.

23. Remove the two lower engine covers and side covers in the wheelarches.


24. Remove the headlamp position sensor (option) and move the sensor aside.


25. Remove the front exhaust pipe. See Front exhaust pipe .


26. Remove the bolt holding the front torque rod to the subframe.


27. Release the clamps holding the power steering pipe.


28. Remove the nuts of the power steering cooling pipe. Suspend the pipe with a 83 95 212 Strap.

29. Release the air filter housing from the subframe.


30. Release the AC pipe from the plastic clips on the subframe.


31. Pull a 83 95 212 Strap around the radiator core and radiator member to keep the core supported.

32. Remove the bolts holding the outer ball couplings to the steering swivel member on both sides.

33. Remove the upper ball joint of the anti-roll bar on both sides.


34. Remove the steering gear bolts.


35. Remove the bolts holding the rear support plates and the 2 rear bolts of the subframe.

36. Insert 83 95 311 Trolley lift below the subframe with 83 94 801 Parent fixture , 83 95 188 Basic fixture and 83 95 196 Holder, front .

37. Remove the 4 remaining bolts holding the subframe.

38. Release the suspension arm from the steering swivel member, lower further and roll the trolley lift away with subframe.

39. Slacken the gearbox drain plug, drain the transmission fluid and retighten the plug.

Tightening torque 50 Nm (37 lbf ft)

40. Remove the rear engine mounting and engine pad.


41. Remove the lower gearbox bolts. Leave one bolt in place until the gearbox is removed.


42. Remove the lower bolt of the starter motor and lower the starter motor.


43. Release the left drive shaft with 87 92 616 Removal tool, drive shafts . Suspend the shaft with a strap.


44. Disconnect the ground lead from the gearbox.

45. Lower the car to the floor.

46. Mark the bolt positions and remove the nuts and bolts from the left engine pad. Lift away the pad.


47. Lower the assembly so that the gearbox is clear of the structural member. Remove the gearbox fixing from the gearbox.


48. Raise the car. Fit 87 92 608 Holder for pillar jack on a pillar jack. Adjust and tighten the tool in the gearbox as illustrated. Use bolts of grade 8.8 that are approx. 20 mm longer than the old bolts.



49. Remove the last bolt between the engine and gearbox. Pull out and lower the gearbox.

Warning

Be careful that the jack does not tip over.


50. Lift the gearbox off the jack and remove the lifting tool from the gearbox.