Transmission. Remove and Install (Vehicles with V6 Engines)
Disconnect battery
Remove, Disconnect
Both front wheels.
Upper engine cover (4 bolts)
Air intake duct (2, disconnect cable tie. hose clamp.
retaining clip, remove rubber funnel).
Retaining clip for air intake duct(1. access to front engine transport shackle), vacuum line
(2) for brake servo from intake manifold.
Wiring trough from intake manifold (4 Torx bolts E 10,3).
Detach accelerator Bowden cable from actuation.
Disconnect accelerator Bowden cable from counterhold on intake manifold.
Fluid dipstick.
Unclip wiling harness plug from clamp on intake hose.
Install, Connect
KM-263-B to transport shackles on engine(2 transport cables. 3 shackles. 2 spring hooks).
Remove, Disconnect
Vent line from side cover, disconnect oxygen sensor wiling harness plug (under high voltage distributor).
Remove, Disconnect
Heating hoses from bracket on hydraulic modulator (arrow).
Detach transmission wiring harness from bulkhead
Raise vehicle.
Front exhaust pipe - group L (3 bolts with nuts on catalytic converter, 2 nuts on each exhaust manifold).
Front axle body - group E.
Axle shafts from transmission(with KM-160-2-B on left and soft metal drift on right).
Remove, Disconnect
Bearing cover for intermediate shaft (2 bolts. 1).
Remove intermediate shaft from transmission.
Important!
Transmission fluid escapes, close off openings.
Remove, Disconnect
Front left engine mount from front frame side member -
2 bolts, bracket remains on transmission.
Remove, Disconnect
Oil cooler lines from transmission or side cover (2 hose clamps).
Important
Transmission fluid escapes, close off openings.
Remove, Disconnect
Lower vehicle.
Lower engine on KM-263-B until flange with 3 upper transmission bolts is visible through left wheel housing.
Cable from selector lever positions switch
(remove clip; below battery holder).
Cable from counterhold on transmission (remove clip).
Remove, Disconnect
Cover plate from converter housing (3 bolts, 1).
Converter from drive disc - counterhold drive disc with
KM-517.Unscrew 6 bolts from front of engine oil pan.
Remove, Disconnect
To turn drive disc further, apply box wrench to bolt on reverse of engine oil pan and turn drive disc (arrow) until bolt is accessible from front of engine oil pan.
3 upper bolts for transmission on engine block:Unscrew front upper bolts (2 bolts, 1) through left wheel housing using extension. Rear bolt (2) from vehicle underside using wrench.
Remove, Disconnect
Attach transmission to hydraulic jack with commercially available
Transmission Lifter no. 09 00 094 and Clamp Plate F 09 18 021 and secure with chain.
2 front bolts(arrows) for transmission to engine.
2 rear bolts (arrows) for transmission to engine.Separate transmission from engine (1 guide bushings on engine side ) and carefully lower, to avoid damage to the transmission wiring harness.
Remove, Disconnect
Disconnect 6 wiring harness plugs from transmission wiring harness
Grease centring seat (1) of converter in crankshaft -19 70 206 (90 167 353).Important!
When replacing the transmissions, note that the 2 snide bushings (2) must remain in the engine flange.
Clean
When replacing transmissions: oil cooler Blow through lines in both directions with compressed air.
Inspect
Centring journal (2) of converter for fretting corrosion. clean if necessary.
install, Connect
Transmission wiring harness (6 wiring harness plugs) Raise transmission secure with chain (align engine at a slant).
Tighten (Torque)
2 front and 2 real bolts for transmission to engine -75 Nm.
Converter to chive disc - 30 Nm., counterhold with KM-517. use torque wench with flat box adapter.Cover plate (3 bolts) to converter housing -7 Nm.
Tighten (Torque)
3 upper bolts for transmission to engine (2 with extension, 1 with wrench from underside) - 75 Nm.
Install, Connect
Cable to selector lever position switch, secure with clip. Fasten cable for selector level position switch to counterhold with clip.
Tighten (Torque)
Recut thread in front frame side member:
M 10 x 1.25. insert new bolts with Locking Compound 15 10 177 (90 167 34"). raise hydraulic jack, front left engine mount to front frame side member - 60 Nm.
Remove chain from transmission, lower hydraulic jack.
Tighten (Torque)
Intermediate shaft in Transmission, bearing cover (1) for intermediate shaft to bracket -18 Nm.
Install, Connect
Axle shafts.
Front axle body - group E. front exhaust pipe - group L. route oxygen sensor wiring harness plug upwards and clip in.
Oil cooler lines (2 new hose clamps).Tighten (Torque)
Front wheels to wheel hub -110 Nm.
Lower vehicle.Remove, Disconnect
KM-263-B
Install, Connect
Connect oxygen sensor wiling harness plug
Tighten (Torque)
Retaining clip (1) for air intake duct - 8 Nm.
Injection system wiling trough (4 Torx bolts E 10, 3) to intake manifold - 8 Nm.
Union nut (2) for vacuum line to intake manifold -15Nm.
Install, Connect
Attach accelerator Bowden cable to counterhold and to actuator.
Install wiring harness plug in clamp on air intake hose.
Fasten transmission wiring harness to bulkhead.
Install, Connect
Attach heating hoses to bracket on hydraulic modulator transmission vent hose to side cover.
Air guide duct (1 hose clamp), rubber funnel to air deflector panel.Upper engine cover (4 bolts).
Correct transmission fluid level - group K.
