Mercedes-Benz Cars 2000-05

Transmission Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section. Drain the transmission fluid.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Transfer case
     
    Dipstick tube
     
    Electrical connector shield
     
    Electrical connector
     
    Shift rod
     
    Park interlock cable
     
    Oxygen sensors
     
    Transmission cooler lines
     
    Torque converter cover
     
    Torque converter-to-flexplate bolts
     
    Rear transmission mount
     
    Ground strap
     
    Transmission-to-engine mounting bolts
     
    Transmission
     

  4.  

To install:

  1. Position the transmission on the engine and install the mounting bolts.
  2.  
  3. Install or connect the following:

    Ground strap
     
    Rear transmission mount
     
    Torque converter-to-flexplate bolts: tighten to 31 ft. lbs. (42 Nm)
     
    Torque converter cover
     
    Transmission cooler lines
     
    Oxygen sensors
     
    Park interlock cable
     
    Shift rod
     
    Electrical connector and shield
     
    Transmission dipstick tube
     
    Transfer case
     
    Negative battery cable
     
    Transmission fluid
     

  4.  



Click image to see an enlarged view

Fig. Exploded view of the components associated with manual transmission removal and installation

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Support the transmission with a jack and remove the transmission support assembly (19).
  6.  
  7. Remove or disconnect the following:

    Exhaust support bracket (10) and U-bolt (11)
     
    Heat shield (5)
     
    Front driveshaft (71)
     
    Exhaust system (60) at the rear mount. Use a piece of wire to suspend it.
     
    Speedometer cable (9) or Vehicle Speed Sensor (VSS) (85a)
     
    Clutch hydraulic line (arrow)
     
    Shift linkage clips (32) and shift linkage
     
    Transmission ground strap (27)
     
    Transmission-to-engine mounting bolts
     
    Transmission
     

  8.  

To install:

  1. Apply a light coating of grease to the splines of the input shaft (33).
  2.  
  3. Lift the transmission to the engine.
  4.  
  5. Install or connect the following:

    Transmission mounting bolts
     
    Ground strap
     
    Shift linkage
     
    Clutch hydraulic line
     
    Speedometer cable or VSS
     
    Exhaust system with new gaskets
     
    Driveshaft
     
    Heat shield
     
    Exhaust support bracket and U-bolt
     
    Transmission support
     

  6.  
  7. Check the transmission oil level and add if necessary.
  8.  
  9. Lower the vehicle to the floor and connect the negative battery cable. Bleed the hydraulic clutch system.
  10.  



Click image to see an enlarged view

Fig. Exploded view of the components associated with manual transmission removal and installation

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Support the transmission with a jack and remove the transmission support assembly (19).
  6.  
  7. Remove or disconnect the following:

    Exhaust support bracket (10) and U-bolt (11)
     
    Heat shield (5)
     
    Front driveshaft (71)
     
    Exhaust system (60) at the rear mount. Use a piece of wire to suspend it
     
    Speedometer cable (9) or Vehicle Speed Sensor (VSS) (85a)
     
    Clutch hydraulic line (arrow)
     
    Shift linkage clips (32) and shift linkage
     
    Transmission ground strap (27)
     
    Transmission-to-engine mounting bolts
     
    Transmission
     

  8.  

To install:

  1. Apply a light coating of grease to the splines of the input shaft (33).
  2.  
  3. Lift the transmission to the engine.
  4.  
  5. Install or connect the following:

    Transmission mounting bolts
     
    Ground strap
     
    Shift linkage
     
    Clutch hydraulic line
     
    Speedometer cable or VSS
     
    Exhaust system with new gaskets
     
    Driveshaft
     
    Heat shield
     
    Exhaust support bracket and U-bolt
     
    Transmission support
     

  6.  
  7. Check the transmission oil level and add if necessary.
  8.  
  9. Lower the vehicle to the floor and connect the negative battery cable. Bleed the hydraulic clutch system.
  10.  



Click image to see an enlarged view

Fig. Exploded view of the components associated with manual transmission removal and installation

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Support the transmission with a jack and remove the transmission support assembly (19).
  6.  
  7. Remove or disconnect the following:

    Exhaust support bracket (10) and U-bolt (11)
     
    Heat shield (5)
     
    Front driveshaft (71)
     
    Exhaust system (60) at the rear mount. Use a piece of wire to suspend it
     
    Speedometer cable (9) or Vehicle Speed Sensor (VSS) (85a)
     
    Clutch hydraulic line (arrow)
     
    Shift linkage clips (32) and shift linkage
     
    Transmission ground strap (27)
     
    Transmission-to-engine mounting bolts
     
    Transmission
     

  8.  

To install:

  1. Apply a light coating of grease to the splines of the input shaft (33).
  2.  
  3. Lift the transmission to the engine.
  4.  
  5. Install or connect the following:

    Transmission mounting bolts
     
    Ground strap
     
    Shift linkage
     
    Clutch hydraulic line
     
    Speedometer cable or VSS
     
    Exhaust system with new gaskets
     
    Driveshaft
     
    Heat shield
     
    Exhaust support bracket and U-bolt
     
    Transmission support
     

  6.  
  7. Check the transmission oil level and add if necessary.
  8.  
  9. Lower the vehicle to the floor and connect the negative battery cable. Bleed the hydraulic clutch system.
  10.  



Click image to see an enlarged view

Fig. Exploded view of the components associated with manual transmission removal and installation

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Support the transmission with a jack and remove the transmission support assembly (19).
  6.  
  7. Remove or disconnect the following:

    Exhaust support bracket (10) and U-bolt (11)
     
    Heat shield (5)
     
    Front driveshaft (71)
     
    Exhaust system (60) at the rear mount. Use a piece of wire to suspend it.
     
    Speedometer cable (9) or Vehicle Speed Sensor (VSS) (85a)
     
    Clutch hydraulic line (arrow)
     
    Shift linkage clips (32) and shift linkage
     
    Transmission ground strap (27)
     
    Transmission-to-engine mounting bolts
     
    Transmission
     

  8.  

To install:

  1. Apply a light coating of grease to the splines of the input shaft (33).
  2.  
  3. Lift the transmission to the engine.
  4.  
  5. Install or connect the following:

    Transmission mounting bolts. Tighten transmission bellhousing bolts to 30 ft. lbs. (40 Nm), M6 crankcase bolts to 7 ft. lbs. (9Nm) and the M8 crankcase bolts to 15 ft. lbs. (20 Nm).
     
    Ground strap
     
    Shift linkage
     
    Clutch hydraulic line
     
    Speedometer cable or VSS
     
    Exhaust system with new gaskets
     
    Driveshaft
     
    Heat shield
     
    Exhaust support bracket and U-bolt
     
    Transmission support
     

  6.  
  7. Check the transmission oil level and add if necessary.
  8.  
  9. Lower the vehicle to the floor and connect the negative battery cable. Bleed the hydraulic clutch system.
  10.  

 
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