For 1990-2009 cars

#### Special Tools

• | KM-113-2 Bracket

• | KM-308 Remover/Installer

• | KM-328-B Remover

• | KM-447 Remover/Installer

• | KM-500-A Remover/Installer

• | KM-552 Fixture

• | KM-553-A Fifth Gear Puller

• | KM-556-A Puller Set

• | KM-557-A Remover

• | KM-559-A Puller

• | KM-727 Remover

• | KM-982 Mount

• | KM-983 Remover

• | KM-6115 Bracket for Clutch Housing

• | KM-6155 Guide Pins

• | KM-6335 Thrust Piece

• | MKM-559 Inner Extractor

1. Attach transmission to KM-6115 (2).
2. Attach transmission to KM-113-2 (1) using KM-6115 .
3. Remove left engine damping block bracket.

Remove 3x bolts.

4. Put transmission into neutral.

Important: Shift transmission to neutral position.

5. F17+ MTA: Remove gearshift module. Refer to Transmission Control Replacement.

F17+: Complete the following procedure:

5.1. | Press adjusting pin (2) into adjusting bore.

| Important: The adjusting pin is at the front in the direction of travel.

5.1. | Turn gearshift rod anti-clockwise (in direction of 3rd gear).

| Important: Cover aperture in transmission.

5.2. | Detach gearbox cover (1) from transmission.

Unscrew 4x bolt.

5.3. | Clean sealing surfaces, remove sealant residues.

5.4. | Measure clearance (I) between alignment pin (2) and actuating mechanism (1) of the gearshift rod 3rd/4th gear.

• | Measure with feeler gauge

• | Clearance must be approx. 0.5 mm (0.0197 in)

- | If clearance is too great, drive alignment pin further into the transmission housing with a drift punch and measure clearance again.

- | If clearance is too small: No correction of clearance necessary because the gearshift rod presses the alignment pin into the correct position.

5.5. | Attach gearbox cover to KM-982 (3).

5.6. | Clamp KM-982 in a vice.

5.7. | Remove engaging sleeve for intermediate lever from gearbox cover (I).

Draw out of gearbox cover with KM-328-B (1) and KM-983 -2 (2).

5.8. | Remove guide bolt for connecting link from gearbox cover (II).

Draw out of gearbox cover with KM-328-B and KM-983 -1 (4).

5.9. | Detach retaining ring (5) from intermediate gearshift lever.

5.9.1. | Remove bush (6)

5.9.2. | Remove compression spring (7)

5.9.3. | Remove washer (8)

5.10. | Detach gearbox cover from KM-982 .

5.11. | Remove intermediate gearshift lever (1).

Turn gearshift rod (2) with gearshift finger in the direction of the arrow.

5.12. | Remove gearshift rod from gearbox cover.

Knock roll pin out of gearshift finger (3) with drift punch. Note recess in cover.

| Important: Do not further dismantle gearbox cover.

5.13. | Prise seal ring (4) out of gearbox cover.

6. Unscrew reversing lamp switch (1).

Important: Place collecting pan underneath - transmission fluid will escape

7. Remove end shield cover.

Unscrew 9x bolt. If necessary, release the end shield cover by striking it gently with a rubber mallet.

Detach end shield cover gasket.

Important: When dismantling the end shield it is essential to use KM-6155 (2) as otherwise the shaft seal ring of the central release will be damaged.

Important: Be careful of guide sleeves, magnet (3) and spacer washer (4) for axle reverse idler gear.

8. Screw KM-6155 into threaded bores.
9. Detach end shield.

Unscrew 4x bolt (arrows).

10. Check all parts for damage. Replace damaged components.
11. Clean sealing surfaces.
12. Detach KM-6155 .
13. Attach end shield to KM-552 (2).
14. Attach end shield to KM-113-2 (1) using KM-552 .

Important: Micro-encapsulated fastening bolts. If fastening bolts are stiff, heat end shield with hot-air dryer to approximately 80°C (176°F).

15. Remove bearing support (1) with rocker arm (2) from end shield.

Unscrew 2x bolt.

16. Remove 5th gear (driven).

• | Detach retaining ring from synchro body (1)

• | Pull gear wheel, 5th gear, and synchro body, 5th gear, away from main shaft with KM-559-A (2)

• | Remove 2x needle bearing for gear wheel, 5th gear

17. Detach gear wheel, 5th gear (driving) (2) from drive shaft (3). Remove retainer (1).

Important: Ensure KM-553-A is correctly seated on the gear wheel, 5th gear (driving).

18. Detach gear wheel, 5th gear, (driving) from drive shaft with KM-553-A (1).

Place thrust piece (2) from KM-553-A on drive shaft.

Important: Micro-encapsulated fastening bolts. If fastening bolts are stiff, heat end shield with hot-air dryer to approximately 80°C (176°F).

19. Detach bearing support (2) with pawl (1) from end shield.

Remove 2x bolts (arrow).

20. Remove locking plugs (arrows) from end shield.

Remove locking plugs with KM-727 (2) and KM-328-B (1).

21. Detach bridge (1) for end shield locking bolt. The bridge will push out if 3rd gear is then engaged.

Important: Micro-encapsulated fastening bolts. If fastening bolts are stiff, heat end shield with hot-air dryer to approximately 80°C (176°F).

22. Unscrew 2x bolt (2).
23. Engage 2nd gear and 5th gear.

Engage 2x gear with shift carrier (arrows).

Important: Relieve pressure on gearshift rod guides - for this, support gearshift rods above with wood (1).

24. Remove shift fork, 3rd/4th gear and reverse gear.

• | Drive roll pins out of 3rd/4th gear shift fork (3) and reverse gear shift fork (6) using KM-308

• | Take out gearshift rod (2), gearshift rod reverse gear and shift fork

25. Remove gear shift driver.

Remove 5th gear shift driver (4) from end shield.

26. Remove locking pins (5).

Remove roll pin for catch from end shield.

Important: Relieve pressure on gearshift rod guides - for this, support gearshift rods (1) above with wooden wedge (2).

27. Remove 1st/2nd gear shift fork.

• | Drive roll pin (3) out of 1st/2nd gear shift fork (4) using KM-308

• | Take out shift fork with gearshift rod

Important: Collect main shaft, drive shaft and reverse idler.

28. Remove main shaft and drive shaft.

• | Detach end shield from KM-552

| Important: To ensure that both shafts are pushed out evenly, press harder on the main shaft side. Take care that the gear wheel, 1st gear, is not in contact with the press.

• | Press main shaft and drive shaft out as shown using KM-6335 (1)

• | Collect main shaft, drive shaft and reverse idler

Important: Note that retaining ball is released.

29. Remove reverse gear axle (1).

| Important: Use protective jaws

• | Clamp reverse gear spindle in vice

• | Carefully knock off end shield with brass punch

30. Remove bearing for main and drive shafts.

• | Remove 2x retaining rings (2)

• | Press out 2x bearings using KM-500-A -5 (3)

31. Clean all parts and sealing surfaces.
32. Check all parts. Replace damaged components.

Important: Place collecting pan underneath - transmission fluid will escape

33. Detach differential cover (1).

Unscrew 10x bolt.

34. Mark position of bearing race (2) in respect of transmission (arrow).
35. Remove bearing race with KM-447 (2).

Remove retaining plate (1) from bearing race - unscrew bolt.

36. Remove differential downwards.
37. Detach pressure line (1). Unscrew union nut.
38. Remove central release. Remove 3x bolt (arrow).
39. Check seal ring (1) on central release for damage. Replace damaged components.
40. Remove pressure line (1).

• | Unlatch fastening sleeve for pressure line on clutch housing (arrows)

• | Draw fastening sleeve with pressure line upwards and slightly out of transmission

• | Detach fastening sleeve for pressure line - carefully disengage retaining lugs (3)

• | Remove pressure line

41. Check all parts for damage. Replace damaged components.
42. Remove needle bearing (3) for drive shaft.

Remove needle bearing from transmission housing with KM-556-A (1) and MKM-559 (2).

43. Remove roller bearing (4) for main shaft.

Remove roller bearing from transmission housing with KM-556-A (6) and KM-556-A -2 (5).

44. Remove 2x axle shaft seal ring with KM-557-A -1 (2) and KM-557-A -2 (1) from transmission housing.
45. Remove transmission housing from KM-6115 .