Removing
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 mudguard from under the engine.
3. Drain the gearbox oil and replace the oil fill 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 wiring from the transmission together with the reversing light switch, speedometer drive sensor and ground bus.
9. Remove from the brackets and move aside the harness for the brake pad wear indicator lamp and the ABS system.
10. Using a screwdriver blade as a pry bar, disconnect the three gear selector pins from their respective ball joints on the gearbox.
11. Remove cable, suspension and RPM/TDC sensor.
12. Move to the side of the air conditioning pipe and the steering gear of the power steering.
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. Disconnect the electrical connector if present. 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 O-ring from the gearbox housing.
17. Using a winch, raise the left side of the power unit just enough so that the weight of the power unit is supported only by the winch.
18. Place a jack under the gearbox and raise it just enough so that the weight of the gearbox is supported by the jack.
19. Unscrew the central nut of the left suspension support of the power unit. Unscrew the two bolts and remove the rubber pad from the unit suspension.
20. On models with a clutch disengagement type "tractive effort" remove the pin or unscrew the fastening bolt.
21. Remove the clutch release lever from the top of the clutch release shaft. Disconnect the release bearing from the clutch release fork.
22. Make marks through the center of the release fork shaft and mark the position of the shaft in relation to the gearbox housing (marks are indicated by arrows).
23. Unscrew the bolts and remove the lower flywheel protective plate.
24. Unscrew a bolt of fastening of a transmission to the back party of the block of cylinders.
25. Supporting the gearbox with a jack, unscrew the remaining bolts securing the gearbox to the engine.
26. Lower the power unit and move the transmission on a jack away from the engine. Lower the gearbox under the vehicle.
27. Make a second mark marking the position of the clutch release shaft in relation to the transmission case after the transmission has been removed, noting the angle the release fork has turned.
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 sealing rings of the drive shafts;
- 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 the gearbox was removed. Lubricate the threads of the left suspension mounting bolt with an anti-screwing agent;
- tighten all bolts and nuts to the required torque;
- install drive shafts;
- remove the oil from the gearbox.