Transmission - Removal, Replacement And Installation - 1 Of 2

• Auxiliary Transmission, Bevel Gear And Overdrive (Ambulance; 2001-2002)
  • Bevel gear, replacing
    • Notes
    • Removal
      • Preparations
      • Disconnecting the front suspension components
      • Removing front end components, continued
      • Removing the control arm from the ball joint
      • Removing the drive shaft
      • Removing the propeller shaft
      • Removing bevel gear
    • Installation
      • Notes
      • Installing the bevel gear
      • Installing the propeller shaft
      • Installing members
      • Installing the drive shaft and bearing cap on the pilot bearing for the shaft
      • Installing the drive shaft
      • Checking the oil level in the bevel gear
      • Installing front suspension components
      • Installing front end components, continued
  • Bleed valve bevel gear, replacing
    • Removing the brass pipe
    • Filling with oil
  • Replacing the pinion seal for the bevel gear
    • Notes
    • Removal
      • Notes
      • Marking the propeller shaft and flange
      • Removing the propeller shaft
      • Removing the nuts for the bevel gear flange
      • Removing flange
      • Removing seal
    • Installation
      • Installing the seal
      • Installing the flange on the pinion
      • Installing propeller shaft
      • Installing the three-way catalytic converter (TWC)
      • Checking the oil level in the bevel gear
    • Replacing the three-way catalytic converter (TWC)
      • Notes
      • Removing the three-way catalytic converter (TWC)
      • Installing the three-way catalytic converter (TWC)
  • Sealing ring, crown wheel shaft, left-hand side, replace
    • Notes
    • Preparatory work
      • Removing bevel gear
    • Removal
      • Removing the sealing ring
      • Draining the bevel gear oil
    • Installation
      • Installing the sealing ring
    • Finishing
      • Installing the bevel gear
      • Filling with oil
  • Sealing rings bevel gear, replacing
    • Notes
    • Sealing ring for driveshaft front right side, replacing
      • Removing the sealing ring
      • Installing a new sealing ring
    • Sealing ring for crown wheel shaft for bevel gear, replacing
      • Marking the position of the adjustment nut
      • Removing the adjustment nut
      • Removing the sealing ring
      • Installing the sealing ring
      • Installing the adjustment nut
      • Checking marking
• Auxiliary Transmission, Bevel Gear And Overdrive (Ambulance; 2003-2004)
  • Bevel gear
    • Notes
    • Removal
      • Preparations
      • Only D5244T/T2
      • Disconnecting the front suspension components
      • Removing front end components, continued
      • Draining AW transmission oil
      • Removing spring strut from control arm
      • Removing the drive shaft
      • Removing the propeller shaft
      • Removing the propeller shaft, front
      • Only D5244T-T3
      • Removing bevel gear
      • Greasing splines
    • Installation
      • Installing the bevel gear
      • Only D5244T/T2
      • Installing the propeller shaft
      • Installing members
      • Installing the drive shaft and bearing cap on the pilot bearing for the shaft
      • Installing the sealing ring for the CV joint housing on the stub axle
      • Installing the drive shaft
      • Checking the oil level in the bevel gear
      • Installing ball joint nut
      • Installing front suspension components
      • Filling transmission oil, AW
    • Sealing ring connecting socket drive shaft/differential, replacing
  • Pinion seal bevel gear, replacing
    • Notes
    • Removal
      • Removing the three-way catalytic converter (TWC)
      • Marking the propeller shaft and flange
      • Removing the propeller shaft
      • Removing the nuts for the bevel gear flange
      • Removing the flange
      • Removing the pinion seal
    • Installation
      • Installing the seal
      • Installing the flange on the pinion
      • Installing the propeller shaft
      • Installing the three-way catalytic converter (TWC)
      • Checking the oil level in the bevel gear
    • Three-way catalytic converter (TWC), replacing
  • Sealing ring, crown wheel shaft, left-hand side, replace
    • Notes
    • Preparatory work
      • Removing bevel gear
    • Removal
      • Removing the sealing ring
      • Draining the bevel gear oil
    • Installation
      • Installing the sealing ring
    • Finishing
      • Installing the bevel gear
      • Filling with oil
  • Sealing rings bevel gear, replacing
    • Notes
    • Sealing ring for drive shaft front right side, replacing
      • Removing the sealing ring
      • Installing a new sealing ring
    • Sealing ring for crown wheel shaft for bevel gear, replacing
      • Marking the position of the adjustment nut
      • Removing the adjustment nut
      • Removing the sealing ring
      • Installing the sealing ring
      • Installing the adjustment nut
      • Checking the marking
  • Transfer case ventilation valve
    • Removing the brass pipe
    • Filling with oil
• Auxiliary Transmission, Bevel Gear And Overdrive (B5254T2, Aw50/51 AWD; 2004-2006)
  • Bevel gear
    • Notes
    • Removal
      • Preparations
      • Only D5244T/T2
      • Disconnecting the front suspension components
      • Removing front end components, continued
      • Draining AW transmission oil
      • Removing spring strut from control arm
      • Removing the drive shaft
      • Removing the propeller shaft
      • Removing the propeller shaft, front
      • Only D5244T-T3
      • Removing bevel gear
      • Greasing splines
    • Installation
      • Installing the bevel gear
      • Only D5244T/T2
      • Installing the propeller shaft
      • Installing members
      • Installing the drive shaft and bearing cap on the pilot bearing for the shaft
      • Installing the sealing ring for the CV joint housing on the stub axle
      • Installing the drive shaft
      • Checking the oil level in the bevel gear
      • Installing ball joint nut
      • Installing front suspension components
      • Filling transmission oil, AW
  • Pinion seal bevel gear, replacing
  • Sealing ring, crown wheel shaft, left-hand side, replace
  • Sealing rings bevel gear, replacing
  • Transfer case ventilation valve
• Gear Selector Assembly, Gear Selector (4T65EV; 1999-2005)
  • Boot, gear selector, replacing
    • Removal
      • Remove the boot and the gear selector knob
    • Remove the panel with the gear selector boot
    • Replace the gear selector boot
    • Reinstall the panel on the center console
  • Gear selector knob, Geartronic, replacing
    • Removal
      • Removing the boot from the gear selector knob
      • Removing the lock bracket from the gear selector knob
    • Removing the gear selector knob
    • Installation
      • Installing the gear selector knob
      • Installing the lock bracket on the gear selector knob
      • Installing the top panel
• Gear Selector Assembly, Gear Selector (4T65EV, L. H. D; 1999-2005)
  • Cable key interlock, replacing
    • Removal
      • Preparations
    • Disconnect the cable from the ignition switch
    • Disconnect the cable from the gear selector assembly
    • Remove the cable from the steering column
    • Installation
      • Install the cable
      • Connect the cable to the gear selector mounting
      • Initial setting of the key lock cable (adjusting)
      • Finishing work
  • Gear selector cables, replacing
    • Notes
    • Removal
      • Remove the air cleaner (ACL) housing
      • Remove the center console
      • Remove the transmission cable from the bracket and from the lever at the transmission
      • Remove the gear selector cable
      • Remove the gear selector cable at the firewall
    • Installation
      • Preparations for installation
      • Install the gear selector cable from the inside of the passenger compartment
      • Feed the gear selector cable in from the inside
      • Position the gear selector cable behind the steering gear
      • Install the gear selector cable on the gear selector
      • Install the gear selector cable on the transmission
  • Gear selector knob, replacing
    • Removal
      • Remove the gear selector knob
    • Installation
      • Install the gear selector knob
  • Gear selector lever assembly Geartronic, replacing
    • Removal
      • Removing the center console
        • Remove the side panels
        • Remove the gear selector lever boot and the connector
        • Separate the panel and top panel
        • Remove the panel (1) over the parking brake lever
        • Pull up front edge of the bracket
        • Preparations for removing the center console
        • Remove the center console
      • Fold the top panel with the boot away from the gear selector lever
      • Remove the stop for the gear selector assembly
      • Remove the cables and the gear selector assembly
      • Transfer the solenoid with the connector
    • Installation
      • Install the cable and the gear selector assembly
      • Install the stop for the gear selector assembly
      • Install the gear selector knob and the boot
      • Install the locking sleeve for the boot
      • Initial setting of the key lock cable (adjustment)
    • Installing the center console
      • Install the center console
      • Install the panel for the parking brake lever
      • Install the panel and connector
      • Reinstall the side panels
    • Install the center console
  • Gear selector lever assembly, replacing
    • Removal
      • Remove the gear selector knob
    • Remove the center console
    • Remove the gear selector assembly
    • Transfer the solenoid with the connector
    • Installation
      • Install the gear selector assembly on the bodywork
      • Install the top panel and boot
      • Install the center console
      • Install the gear selector knob
  • Solenoid, back-up (reverse) inhibitor, replacing
    • Removal
      • Removing the center console
      • Removing the cable from the gear selector assembly
      • Removing the solenoid
    • Installation
      • Installing the solenoid
      • Installing the cable on the gear selector assembly
      • Installing the center console
  • Stop, gear selector lever assembly, replacing
    • Removal
      • Removing the center console
      • Removing the boot from the gear selector
      • Removing the gear selector knob
      • Removing the gear selector assembly stop
      • Removing the printed circuit board for the gear selector assembly stop
    • Installation
      • Installing the gear selector assembly stop
      • Installing the gear selector knob
      • Installing the boot on the gear selector
      • Installing the center console
  • Top panel, Geartronic, replacing
    • Removal
      • Removing the top panel
      • Removing the gear selector knob
      • Removing the center console
      • Removing the gear selector assembly stop
      • Removing the printed circuit board from the gear selector assembly stop
      • Removing the boot and the switches from the gear selector assembly
      • Removing and transferring the boot from the top panel
    • Installation
      • Installing the boot
      • Installing the printed circuit board on the gear selector assembly stop
    • Installing the gear selector assembly stop on the gear selector assembly
    • Installing the top panel
    • Installing the gear selector knob and lock bracket
    • Installing the center console
  • Top panel, replacing
    • Removal
      • Removing the gear selector knob
      • Removing the center console
      • Removing the top panel and connectors from the gear selector assembly
      • Removing the boot from the top panel
    • Installation
      • Installing the boot on the top panel
      • Installing the top panel and connectors on the gear selector assembly
      • Installing the gear selector knob
      • Installing the center console
• Gear Selector Assembly, Gear Selector (4T65EV-Gt; 1999-2006)
  • Boot, gear selector, replacing
  • Gear selector knob, Geartronic, replacing
• Gear Selector Assembly, Gear Selector (4T65EV-Gt, L. H. D; 1999-2006)
  • Cable key interlock, replacing
  • Gear selector cables, replacing
  • Gear selector knob, replacing
  • Gear selector lever assembly Geartronic, replacing
  • Gear selector lever assembly, replacing
  • Solenoid, back-up (reverse) inhibitor, replacing
  • Stop, gear selector lever assembly, replacing
  • Top panel, Geartronic, replacing
  • Top panel, replacing
• Gear Selector Assembly, Gear Selector (Ambulance; 2003-2004)
  • Boot, gear selector, replacing
    • Removal
      • Removing the gear selector knob
      • Removing the panel
      • Removing the top panel
      • Removing the boot from the top panel
    • Installation
      • Installing a new boot
      • Installing the top panel
      • Installing the gear selector knob
  • Cable key interlock, replacing
    • Removal
      • Preparations
    • Removing the mechanical cable from the ignition switch
    • Removing mechanical cable from gear selector assembly
    • Removing the mechanical cable from the steering column
    • Installation
      • Installing the mechanical cable
      • Installing the mechanical cable on the mounting for the gear selector assembly
      • Initial setting of the key lock cable (adjusting)
      • Finishing work
  • Gear selector cables, replacing
    • Notes
    • Removal
      • Removing the air cleaner (ACL) housing
      • Removing the center console
      • Remove the gear selector cables from the bracket and from the lever on the transmission
      • Removing mechanical cable from gear selector assembly
      • Removing the cable at the firewall
    • Installation
      • Preparations for installation
      • Installing the mechanical cable
      • Installing mechanical cable for gear selector assembly
      • Installing the service clips
      • Installing the center console
      • Installing the gear selector cable on the transmission
      • Installing the air cleaner (ACL) housing
      • Installing the front wheels
  • Gear selector knob, Geartronic, replacement
    • Removal
      • Removing the lock bracket from the gear selector knob
      • Removing the gear selector knob
      • Removing the panel
      • Removing the top panel
    • Installation
      • Installing the gear selector knob
      • Installing the lock bracket on the gear selector knob
      • Installing the top panel
  • Gear selector knob, replacing
    • Removal
      • Removing the gear selector knob
    • Installation
      • Installing the gear selector knob
  • Gear selector lever assembly Geartronic, replacing
    • Notes
    • Removal
      • Removing the center console
      • Removing the gear selector knob
      • Removing the top panel from the gear selector assembly
      • Removing the gear selector assembly stop
      • Removing the gear selector assembly and cables
    • Installation
      • Notes
      • Installing the cables and gear selector assembly
      • Installing the gear selector assembly stop
      • Installing the top panel on the gear selector assembly
      • Installing gear selector knob
      • Initial setting of the key lock cable (adjusting)
    • Installing the center console
  • Gear selector lever assembly, replacing
    • Notes
    • Removal
      • Removing the center console
      • Removing the gear selector knob
      • Removing the top panel from the gear selector assembly
    • Removing the gear selector assembly and cables
    • Installation
      • Notes
      • Installing the gear selector assembly and mechanical cables
      • Installing the top panel on the gear selector assembly
      • Installing gear selector knob
      • Installing the center console
    • Printed circuit board gear selector assembly/top panel, replacing
      • Removal
      • Installation
  • Printed circuit board gear selector assembly/top panel Geartronic, replacing
    • Removal
      • Removing the gear selector knob
      • Removing the center console
      • Removing the top panel from the gear selector assembly
      • Removing the gear selector assembly stop
      • Removing the printed circuit board from the gear selector assembly stop
      • Removing the gear selector boot from the top panel
    • Installation
      • Installing the printed circuit board on the holder and gear selector assembly stop
      • Installing the gear selector assembly stop
      • Installing the top panel on the gear selector assembly
      • Installing the gear selector knob
      • Checking the shift positions
      • Installing the center console
  • Printed circuit board gear selector assembly/top panel, replacing
    • Removal
      • Removing the gear selector knob
      • Removing the center console
      • Removing the top panel from the gear selector assembly
      • Removing the gear selector boot from the top panel
    • Installation
      • Installing the gear selector boot on the top panel
      • Installing the top panel on the gear selector assembly
      • Installing the gear selector knob
      • Installing the center console
  • Solenoid, back-up (reverse) inhibitor, replacing
    • Removal
      • Preparations
      • Removing the solenoid
    • Installation
      • Installing the solenoid
      • Finishing work
• Gear Selector Assembly, Gear Selector (B5254T2, Aw50/51 AWD; 2005-2006)
  • Boot, gear selector, replacing
  • Cable key interlock, replacing
  • Gear selector cables, replacing
  • Gear selector knob, Geartronic, replacement
  • Gear selector knob, replacing
  • Gear selector lever assembly Geartronic, replacing
  • Gear selector lever assembly, replacing
  • Printed circuit board gear selector assembly/top panel Geartronic, replacing
  • Printed circuit board gear selector assembly/top panel, replacing
• Gear Selector Assembly, Gear Selector (B5254T2, Aw55-50/51SN; 2004-2006)
  • Boot, gear selector, replacing
    • Overview
    • Removal
      • Removing the gear selector knob
      • Removing the panel
      • Removing the top panel
      • Removing the boot from the top panel
    • Installation
      • Installing a new boot
      • Installing the top panel
      • Installing the gear selector knob
  • Cable key interlock, replacing
    • Overview
    • Removal
      • Preparations
    • Removing the mechanical cable from the ignition switch
    • Removing mechanical cable from gear selector assembly
    • Removing the mechanical cable from the steering column
    • Installation
      • Installing the mechanical cable
      • Installing the mechanical cable on the mounting for the gear selector assembly
      • Initial setting of the key lock cable (adjusting)
      • Finishing
  • Gear selector cables, replacing
    • Overview
    • Removal
      • Removing the air cleaner (ACL) housing
      • Removing the center console
      • Remove the gear selector cables from the bracket and from the lever on the transmission
      • Removing mechanical cable from gear selector assembly
      • Removing the cable at the firewall
    • Installation
      • Preparations for installation
      • Installing the mechanical cable
      • Installing mechanical cable for gear selector assembly
      • Installing service clips
      • Installing the center console
      • Installing the gear selector cable on the transmission
      • Installing the air cleaner (ACL) housing
      • Installing the front wheels
  • Gear selector knob, Geartronic, replacing
    • Removal
      • Removing the lock bracket from the gear selector knob
      • Removing the gear selector knob
      • Removing the panel
      • Removing the top panel
    • Installation
      • Installing the gear selector knob
      • Installing the lock bracket on the gear selector knob
      • Installing the top panel
  • Gear selector knob, replacing
    • Overview
    • Removal
      • Removing the gear selector knob
    • Installation
      • Installing the gear selector knob
      • Installing the lock bracket on the gear selector knob
    • Gear selector knob, Geartronic, replacing
      • Notes
      • Removal
      • Installation
  • Gear selector lever assembly Geartronic, replacing
    • Overview
    • Removal
      • Removing the center console
      • Removing the gear selector knob
      • Removing the top panel from the gear selector assembly
      • Removing the gear selector assembly stop
      • Removing the gear selector assembly and cables
    • Installation
      • Installing the cables and the gear selector assembly
      • Installing the gear selector assembly stop
      • Installing the top panel on the gear selector assembly
      • Installing gear selector knob
      • Initial setting of the key lock cable (adjusting)
    • Installing the center console
  • Gear selector lever assembly, replacing
    • Overview
    • Notes
    • Removal
      • Removing the center console
      • Removing the gear selector knob
      • Removing the top panel from the gear selector assembly
    • Removing the gear selector assembly and cables
    • Installation
      • Notes
      • Installing the cables and gear selector assembly
      • Installing the top panel on the gear selector assembly
      • Installing gear selector knob
      • Installing the center console
    • Printed circuit board gear selector assembly/top panel, replacing
      • Notes
      • Removal
      • Installation
  • Printed circuit board gear selector assembly/top panel Geartronic, replacing
    • Overview
    • Removal
      • Removing the gear selector knob
      • Removing the center console
      • Removing the top panel from the gear selector assembly
      • Removing the gear selector assembly stop
      • Removing the printed circuit board from the gear selector assembly stop
      • Removing the gear selector boot from the top panel
    • Installation
      • Installing the printed circuit board on the holder and gear selector assembly stop
      • Installing the gear selector assembly stop
      • Installing the top panel on the gear selector assembly
      • Installing the gear selector knob
      • Checking the shift positions
      • Installing the center console
  • Printed circuit board gear selector assembly/top panel, replacing
    • Overview
    • Removal
      • Removing the gear selector knob
      • Removing the center console
      • Removing the top panel from the gear selector assembly
    • Installation
      • Installing the top panel on the gear selector assembly
      • Installing the center console
      • Installing the gear selector knob
  • Solenoid back-up (reverse) inhibitor, replacing
    • Notes
    • Removal
      • Preparations
      • Removing the solenoid
    • Installation
      • Installing the solenoid
      • Finishing
  • Gear selector knob, Geartronic, replacement
  • Solenoid, back-up (reverse) inhibitor, replacing
• Gear Selector Assembly, Gear Selector (B5254T2, Aw55-50/51SN; 2005-2006)
  • Cable key interlock, replacing
  • Gaiter, gear selector, replacement
    • Notes
    • Removal
      • Removing the gear selector knob
      • Removing the panel
      • Removing the gaiter from the top panel
    • Installation
      • Installing the gaiter
      • Installing the top panel
      • Installing the gear selector knob
  • Gear selector cables, replacing
  • Gear selector knob, Geartronic, replacement
  • Gear selector knob, replacing
  • Gear selector lever assembly Geartronic, replacing
  • Gear selector lever assembly, replacing
  • Printed circuit board gear selector assembly/top panel Geartronic, replacing
  • Printed circuit board gear selector assembly/top panel, replacing
  • Solenoid, back-up (reverse) inhibitor, replacing
• Transmission, Automatic (Ambulance; 2001-2002)
  • Control system, replacing
    • Notes
    • Preparatory work
      • Engine wash
      • Transmission fluid, draining
      • Flushing the transmission
      • Removing the air cleaner (ACL) housing
      • Removing the cable harness
      • Removing components
    • Removal
      • Removing the control system
      • Replacing the sealing rings.
      • Checking the gear selector slider
    • Installation
      • Installing the control system
      • Installing the control system cover
    • Finishing
      • Installing components
      • Installing the cable harness and transmission cables.
      • Assembling the connectors
      • Installing the connectors and cable harness
      • Installing the connector and cable harness
      • Oil level, checking and adjusting
      • Installing splashguard under engine
  • Cover brake cylinder B4 automatic transmission, replacing
    • Notes
    • Preparatory work
      • Removing components
      • Cleaning the cover
    • Removal
      • Removing cover
      • Removing cover, continued
      • Checking the cover
    • Installation
      • Replacing the cover
      • Installing the snap ring
      • Adapting the control module
    • Finishing
      • Checking the function of the transmission
  • Gearbox, removing
    • Notes
    • Preparatory work
      • Filling in Diagnostic and Check lists
    • Removal
      • Disconnecting the battery lead
      • Removing engine compartment components
      • Removing components from the gearbox
      • Removing the gearbox mounting screws
      • Removing the coolant hose from the passenger compartment heater
      • Installing the lifting beam and lifting hook on the engine lifting eyelet
      • Removing the air baffle and splash guard under the engine
      • Removing the screw for the cable duct
      • Removing the cross members from the body
      • Removing the screws and nuts for the engine pads, torque rod
      • Measuring the position of the tie rod in the steering gear
      • Exposing the steering shaft joint
      • Removing front suspension components (both sides)
      • Preparations when removing gearbox
      • Preparations for lowering the sub-frame
      • Removing the right-hand drive shaft
      • Removing the left-hand drive shaft
      • Lowering the sub-frame
      • Removing bevel gear
      • Removing the rear engine mounting
      • Removing the screws from the torque converter
      • Removing the oil pipe from the gearbox
      • Lowering the engine and the gearbox
      • Installing the fixture on the mobile jack and gearbox
      • Removing all the screws for the gearbox and engine
      • Removing the gearbox