Hi everybody. Iam A mercedes specialist and have quite a lot of experience removing various vehicle gearboxes etc. This one though has got me stumped

I have removed all the gearbox bolts and everything holding the box in. It is a 2.0 2001 4wd manual. The transfer case is loose but hanging onto the gearbox and I cannot create enough space to remove it. I have completely dropped the sub frame. My problem is i cannot remove the gearbox it seems to be stuck on the input shaft I have tried everything including removing the slave cylinder, but the box will not come out. I can move it back off the dows but thats it. Please help i need my ramp back, and do not want to damage anything due to ignorance. either. Has this vehicle got a dual mass flywheel. any help or advice would be appreciated.

 

This my sound stupid but have you tryed rotating the gear box back and forth while pulling on it? it just may be stuck on a gear tooth. This seems like one of those "mufferys law" problems, the wayu explained how you disassembled it, it should come right off. If you figure it out, let us know so we can help the next person with this problem. Good Luck

 

VERY IMPORTANT! Make sure you remove the controller arm from the top of the trans! (the arm which the slave cylinder pushes to actuate the clutch) It's an undocumented proceedure that if you don't do, it makes it almost impossible to separate the trans from the engine. I read some posts on this website and others about people trying to separate the trans from the engine with crowbars and the like, only to destroy the throwout bearing and the pressure plate spring. The controller arm forks will not disengage the throwout bearing (which in turn is connected to the pressure plate springs.) Simply removing the arm on top of the trans allows the forks to disengage and the trans will easily slide out.

 

thanks rtdurbulance you were right any tips for going back together. ignorance eh!!

 

[align=left] Reengage the throw out bearing with the controller forks.

You have to make sure the controller forks reengage the throwout bearing properly when you reassemble the trans to the engine. You can peer into the bellhousing in the holes underneath. Once you remove the trans, you can see how the forks engage the throwout bearing, and plan your actions to reassemble properly.


Remove the motor mount brackets!

I found that removing the motor mount brackets (on the trans...front, rear, left) was a really big help when I tried to put the trans back in. It's hard to refit the trans if you have to fight the brackets. It was much easier when I removed them. Once the trans was in place and bolted to the engine, it was easy to put the brackets back on the trans.

That's it, hope it helps.

 

it is a pull style clutch not a push style ( release bearing pulls on fingers of pressure plate instead of pushing fingers in towards engine) like u would normally see on most manual transmissions....so u MUST remove nut for clutch linkage arm on top of trans in order for it to turn far enough to release the release bearing from fork and allow removal of transmission....Failure to do so will result in breaking stuff before it will ever come apart....