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Gearbox (mechanical clutch), removal

Gearbox (mechanical clutch), removal

Important

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 cable tie ends.



1. Place the car on a lift.


2. Place wing protectors over the wings to prevent soiling and damage to the paintwork.

3. Remove the covers (both covers on the V6 engine) over the intake manifold or resonator with hoses and mass air flow sensor.

4. Detach the battery leads from the battery.

5. Remove the battery.

6. Engage 4th gear and remove the plastic plug from the gearbox. Lock 4th gear in the gearbox by fitting locking pin 87 92 335.


7. Loosen the clamp securing the selector rod to the linkage in the gearbox from above.

8. Lift up the selector lever gaiter. Engage 3rd gear so that the selector rod disengages from the linkage and fit locking pin 87 92 335 in the gear lever housing.


9. Disconnect the clutch cable from the clutch lever and release the cable's rubber damper from the fastener on the gearbox.

10. Unplug the connector for the reversing lights.


11. Disconnect the positive cable on the battery.

12. Remove the 3 upper gearbox bolts.

13. Unplug the connector(s) to the oxygen sensor and release it/them from the clamps.


14. Fit holder 83 95 287 in the engine's lifting eyes, (For 4-cylinder engines: press the rubber bush out of the left-hand lifting eye.)

15. Position lifting beam 83 93 850 on the wheel housings. Ensure that the beam rests against the edges of the wings. Take the load off engine and gearbox.

16. Raise the car.

17. Remove the front wheels.

18. Remove any clamps on the oxygen sensor cable.

19. Remove the front exhaust system. Turbo: first undo the flange against the turbo and then undo the rear bracket. It is important to remove the exhaust system in this way as the flexible section could otherwise be damaged. Also be careful with the oxygen sensor or sensors.


20. Remove the air shields and cover in the right-hand wheel housing.

21. Remove the suspension arm end piece on both sides. Use tool 89 96 696.


22. Remove the two nuts on the rear engine mounting and the two centre bolts on the subframe.

23. Place lifting trolley 83 94 793 with parent fixture 83 94 801 , front holder 83 94 819 and rear holder 83 94 827 under the subframe and raise the lifting trolley against the subframe.

24. Remove the remaining bolts securing the subframe. There are washers on the rear mountings, take care of them.

25. Lower the trolley lift and push it to one side.

26. Remove the oil drain plug and drain the oil from the gearbox. Screw in the drain plug again.


Tightening torque 50 Nm (37 lbf ft).

27. Extract the left-hand drive shaft using dismantling tool 89 96 654 (Tripode) or 87 92 376 (Rzeppa). Suspend the shaft with cable ties and fit protective plug 87 92 244 in the gearbox.


28. Remove the splash plate by the flywheel.


29. Disconnect the ground leads from the gearbox.

30. Undo the bolts in the engine/gearbox mating face that are accessible from below with the exception of the front one.

31. Undo the two left-hand engine mounting bolts from the body.

32. Remove the mounting from the gearbox.

33. Lower the car and lower the whole drive unit approx. 5 cm.

34. Raise the car and connect holder 87 92 608 (MKM 886). Adjust the lifting tool so that its centre is in line with the and mating face of the gearbox.


35. Mount the gearbox with lifting tool on a single-column jack.

36. Remove the last bolt between the engine and the gearbox.

37. Remove the rear engine-mounting's bracket from the gearbox.


38. Pull out and lower the gearbox.

Warning

Take care not to tip the jack.


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