Table of contents: Removal 🠇 Installation 🠇
Removal the right drive shaft
1 – nuts securing the bearing of the right drive shaft,
2 – rear engine mount bracket,
3 – right drive shaft
Installing the right drive shaft
1 – plastic mounting casing,
2 – right drive shaft
Removal
The gearbox is removed from under the car.
1. Place the hood in a vertical position.
2. Remove the battery and its holder.
3. Remove the air filter assembly.
4. Disconnect the clutch cable from the clutch lever.
5. Disconnect the three shift control connectors from the transmission lever.
6. Disconnect the ground wire from the gearbox.
7. Remove the reversing light switch connector.
8. Remove the starter.
9. Remove the power steering pump supply wire (in vehicles with power steering).
10. Unscrew the bolts securing the stabilizer connectors to the arm.
11. Remove the front wheels of the car.
12. Remove the lower gearbox cover (if available).
13. Drain the oil from the gearbox by unscrewing the plug at the bottom of the outer differential housing.
14. Remove the clutch cover from below.
15. Using a special puller, remove the lower ball joints from the steering knuckles.
16. Disconnect the speedometer drive cable from the gearbox.
17. Disconnect the front exhaust pipe from the exhaust manifold.
18. Remove the crankshaft position sensor (tDC sensor), located in the rear wall of the engine cylinder block (if present in the ignition system).
19. Remove the bracket connecting the rear engine mount bracket to the body.
20. Loosen the nuts securing the right drive shaft bearing to the rear engine mount bracket and turn their bolts half a turn.
21. Move the steering knuckle outward and pull the drive shafts out of the transmission.
22. Hook the gearbox to the hole in the upper edge of its housing using a lift located above the engine compartment.
23. Remove the metal-rubber element of the gearbox bracket.
24. Lower the power unit slightly so that the gearbox is at the very bottom.
25. Hold the power unit in this position using a suitable beam with a holder hooked onto the engine ear.
26. Unscrew the bolts connecting the gearbox to the engine.
27. Remove the gearbox from under the vehicle.
Installation
1. Lubricate the input shaft splines, drive shaft splines and drive shaft sealing ring lips with Molykote BR2 Plus grease.
2. Bring the gearbox to the engine and tighten the mounting bolts.
3. Install the power unit in a horizontal position in the engine compartment.
4. Install the metal-rubber element of the gearbox holder. Tighten the two outer nuts to 15.5 Nm, the middle nut to 35 Nm.
5. Install the plastic mounting cover for the right axle shaft seal ring.
6. Insert the left and right drive shafts into the gearbox. Remove the right drive shaft mounting cover and tighten the right drive shaft bearing mounting nuts to the rear engine mount bracket to 17.5 Nm.
7. Install the holder connecting the rear engine mount bracket to the body. Tighten the holder-to-engine mounting bolts to 35 Nm, and the holder-to-body mounting bolt to 45 Nm.
8. Connect the steering knuckle to the control arms by installing the lower ball joints (tightening torque 30 Nm).
9. Install stabilizer bar connectors to levers (tightening torque 30 Nm).
10. Install the front wheels and lower the vehicle.
11. Fill the gearbox with oil.
12. Adjust the clutch pedal travel.
13. Attach three shift control connectors to the transmission lever.
14. Connect the remaining elements in the reverse order of the removal process.