Removing
1. Disconnect the ground wire from the battery terminal (–).
Attention! This erases the anti-theft code of the radio.
2. Cover the rear wall of the engine compartment with suitable sheet material to prevent damage to the insulating mat when the transmission is lowered.
Attention! On vehicles with an additional heating system, when lowering the gearbox, pay attention to ensure that the coolant hose in the area of the rear wall of the engine compartment is not damaged (arrow).
3. Raise the car, support the gearbox with a special car jack (in a car repair shop) and wooden pads.
4. Remove the bottom protective cover of the engine compartment.
5. Unscrew the motor shaft bearing on the rear cover of the gearbox (arrow).
6. Unscrew the bracket (1) engine mounts on the base of the body frame (arrows).
7. Remove system of release of the fulfilled gases. Unscrew holder (2) at the checkpoint (arrow). Mark the position of the backing plate in advance with a compass (describe a circle), so that it can be installed again later in its original location.
8. Unscrew the screen to the intermediate bearing of the cardan shaft.
9. Loosen the clamping nut on the propeller shaft.
10. Loosen, without unscrewing, the bolts to the intermediate bearing of the cardan shaft.
11. Unscrew the driveshaft at the gearbox. At the same time, leave the hinge disk on the cardan shaft.
12. Loosen the relief sleeves in the pivot flange using a cylindrical rod 10 mm in diameter and approx. 150 mm long.
13. Press the cardan shaft back as far as the intermediate bearing and clamping part allow.
14. Disconnect the piping to the control cylinder on the left side of the hose connection (arrow). Collect spilled brake fluid. Close the joints with stoppers.
15. Remove the shift fork rods from the intermediate levers on the gear shift bracket, having previously pressed the safety clips.
16. Remove the bolts from the starter flange.
17. Unscrew all fixing bolts from the reducer on the intermediate flange. Remove the top three bolts last.
18. Unscrew the wire connecting the battery to the vehicle ground.
19. Turn the gearbox to the left, remove horizontally to the rear and remove it from the clutch.
20. Lower the gearbox.
Attention! Lower the gearbox only when the input shaft is carefully removed from the clutch disc, otherwise the clutch disc may be damaged.
Installation
1. Check the coupling before installation.
2. Check the ease of movement of the clutch release bearing. Lubricate the bearing, e.g. with grease "Liqui Moly V-320". If noises were heard in the operation of the clutch release clutch bearing before disassembly, when the clutch was engaged, replace the bearing.
3. Clean and lightly lubricate with molybdenum paste or molybdenum spray lubricant the input shaft wedge ring gear and centering pins.
Attention! The ring gear of the clutch disc hub for the double-case flywheel is nickel-plated. Therefore, for engines with a volume of 2.2 / 2.8 liters, it is not necessary to lubricate the gear rim of the gearbox input shaft.
4. Engage first gear.
5. Lift, turn to the left and slide the gearbox horizontally into the clutch. If the input shaft of the gearbox does not lock into the clutch disc during insertion, turn the input shaft by hand at the rear in the flange for the propeller shaft.
6. Screw the gearbox to the intermediate flange, while screwing the battery ground wire to the gearbox at the bottom left.
Tightening torque:
- Bolt M 10 x 40 - 55 Nm.
- Bolt M 10 x 45 - 55 Nm.
- Bolt M 10 x 90 - 45 Nm.
7. Tighten the starter motor with two bolts.
8. Hang the shift fork rods on the intermediate levers and fix them with safety clips. At the same time, compress the spring clips, slide the slot into the groove of the shift fork rod and fix it there.
Attention! Use only safety clips with rounded edges (arrow). When assembling, the brackets must engage to ensure a secure fit.
9. Connect the pipeline to the distribution cylinder.
10. Pull the cardan shaft out of the sliding part as far as possible and flange it to the gearbox. To do this, slightly raise the engine and gearbox with a garage jack and wooden spacers.
11. Screw the rear engine mount with bracket firmly to the gearbox.
12. Bolt engine mount bracket firmly to body base frame.
13. Firmly screw on the intermediate bearing of the cardan shaft.
14. Tighten the clamping nut firmly to 35 Nm.
15. Tightly screw on the screen for the intermediate bearing of the cardan shaft.
16. Mount the exhaust system, while checking the rubber rings for porosity and damage.
17. Bleed the air from the clutch control actuator.
18. Check the shift setting.
19. Install the bottom cover of the engine compartment.
20. Lower the car.
21. Remove the sheet material from the engine compartment.
22. Connect the ground wire to the battery terminal (–).
23. Set the time on the clock.
24. Enter the radio's anti-theft code.
Adjustment
Gearshift system
1-2. 1st and 2nd shift fork rod
3-4. 3rd and 4th shift fork rod
5-R. 5th and reverse shift fork rod
1. Set the gearbox to idle (neutral position).
2. Remove the safety clips, then unhook the shift fork stems on the intermediate levers.
- 1-2 = intermediate lever for first and second gear;
- 3-4 = intermediate lever for third and fourth gear;
- 5-R = Intermediate lever for fifth gear and reverse gear.
3. Enter fixing bolt (A) into the holes at the bottom of the gearshift bracket and thereby fix the three intermediate levers.
4. If required, make a fixing bolt according to the specified dimensions.
5. The rods of the gear shift forks must be squeezed out without tension on the bolt with the intermediate lever. If not, loosen the locknut and install this shift fork shield to the appropriate length. Tighten locknut tightly.
6. Lock the shift forks (1) safety brackets.
Attention! Only safety clips with rounded edges can be used (arrow).
7. Remove the fixing bolt.
8. Check the operation of the gearshift system with the engine running. Gears must be installed without jamming.