Table of contents: Removal 🠇 Installation 🠇
Removal
1. Disconnect the negative battery terminal.
2. Raise the front of the car and secure it on stands. Remove the front wheels and remove the fender guard. Remove the splash guard from under the engine.
3. Drain the gearbox oil and replace the oil filler and drain plugs.
4. Remove both drive shafts.
5. From under the car, unscrew the bolts securing the support to the intermediate bearing housing of the drive shaft and the lower frame. Move the support to the side.
6. Remove the air filter housing and intake pipe system.
7. Remove the accelerator cable from the throttle body or high pressure fuel pump.
8. Remove the electrical wiring from the transmission along with the reverse light switch, speedometer drive sensor and ground bus.
9. Remove the brake pad wear indicator lamp and ABS system wiring harness from the brackets and move it to the side.
10. Using a screwdriver blade as a lever, disconnect the three selector rods from their corresponding ball joints on the transmission.
11. Remove the cable, suspension and RPM/TDC sensor.
12. Move the air conditioning pipe and power steering gear to the side.
13. Remove the clutch release cable from the transmission.
14. Unscrew the starter mounting bolts and move the starter to the side without disconnecting the wires from it.
15. Unscrew the bolt and remove the clutch cable hanger.
16. On the speedometer cable drive, remove the pin and remove the cable from the speedometer drive sensor. If present, disconnect the electrical connector. Unscrew the bolt and remove the speedometer drive sensor together with the heat shield. Unscrew the three mounting bolts and remove the speedometer drive sensor housing together with the circular section gasket from the gearbox housing.
17. Using a winch, raise the left side of the power unit so that the weight of the power unit is supported only by the winch.
18. Place a jack under the transmission and raise it enough so that the weight of the transmission is supported by the jack.
19. Unscrew the central nut of the left support of the power unit suspension. Unscrew the two bolts and remove the rubber cushion from the suspension of the unit.
20. On models with a "pull" type clutch release mechanism, remove the pin or unscrew the mounting bolt.
21. Remove the clutch release lever from the top of the release shaft. Disconnect the release bearing from the release fork.
22. Place marks through the center of the clutch release fork shaft and mark the position of the shaft relative to the gearbox housing (the marks are indicated by arrows).
23. Unscrew the bolts and remove the lower flywheel protective plate.
24. Remove the gearbox mounting bolt from the rear of the cylinder block.
25. Supporting the gearbox with a jack, unscrew the remaining bolts securing the gearbox to the engine.
26. Lower the powertrain and jack up the gearbox away from the engine. Lower the gearbox under the vehicle.
27. Make a second mark to indicate the position of the clutch release shaft relative to the transmission housing after the transmission has been removed, noting the angle through which the clutch release fork has rotated.
Aligning the second mark on the clutch release shaft with the mark on the gearbox before installing the gearbox in place
Installation
Installation is carried out in the reverse order of removal, taking into account the following points:
- replace the drive shaft sealing rings;
- check that the guide pins are in place;
- align the mark on the clutch release shaft with the second mark on the gearbox housing made when removing the gearbox. Lubricate the threads of the left suspension mounting bolt with a bolt-loss preventer;
- tighten all bolts and nuts to the specified torque;
- install drive shafts;
- remove oil from gearbox.