Removing
Attention! Removing the gearbox is difficult because access to the bolts securing the gearbox to the engine is limited.
Location of exhaust pipe support bracket bolts
Removing the rear engine/gearbox mount
Removing the speedometer cable from the gearbox
1. Open the hood and place it in a vertical position. Place a thin sheet of steel on the engine bulkhead to protect the bulkhead thermal insulation and brake lines from damage.
2. Remove the ground wire from the battery.
3. On models with an auxiliary heater, be careful not to damage the coolant supply hose located at the rear of the engine compartment when removing the transmission. Unscrew the transmission dipstick tube from the cylinder head.
4. Raise the front of the car and secure it on stands. Remove the engine mudguard.
5. Drain the gearbox oil.
6. Insert a small block of wood between the oil pan and the cross member under the bottom of the vehicle.
7. Remove the exhaust system.
8. If equipped, remove the exhaust system insulation from the bottom of the vehicle to gain access to the propshaft intermediate bearing.
9. Unscrew the brackets for mounting the exhaust system from the bottom of the car (under the driveshaft). Unscrew the two bolts and remove the exhaust pipe mounting bracket from the gearbox (see fig. Location of exhaust pipe support bracket bolts). If equipped, remove the electrical wires from the bracket on the gearbox.
10. Disconnect the propeller shaft from the gearbox output flange.
11. Loosen the propeller shaft intermediate bearing fastening nut, then loosen but do not unscrew the intermediate bearing housing fastening nuts and move the propeller shaft all the way back.
12. Support the gearbox with a jack through a wooden block.
13. Unscrew the rear engine/transmission mount from the bottom of the vehicle and gearbox and remove the mount from under the vehicle (see fig. Removing the rear engine/gearbox mount).
14. Unscrew the mounting bolt and remove the speedometer drive cable from the gearbox (see fig. Removing the speedometer cable from the gearbox).
15. Unscrew the clutch slave cylinder from the gearbox and, without disconnecting the hydraulic tube from it, move it back from the gearbox. Remove the plastic gasket.
Attention! On some models, removing the clutch slave cylinder along with the hydraulic tube does not provide enough clearance to remove the transmission. In this case, before removing the clutch slave cylinder, disconnect the hydraulic hose from it and drain the fluid from the clutch hydraulic system.
16. Working under the vehicle, remove the mounting brackets and disconnect the shift rods from the gear selectors.
17. Remove the starter.
18. Check that the gearbox is securely supported by the jack, then lower it just enough so that the engine rests on a bar inserted between the oil pan and the cross member. When lowering the transmission, be careful not to damage the brake pipes or other elements located on the bulkhead of the engine compartment.
19. Remove the gearbox-to-engine bolts, leaving one bolt on each side of the gearbox. Access to the upper gearbox mounting bolts is very limited. Socket wrenches with extensions and cardan connectors must be used to access these bolts. On some models, the upper gearbox-to-engine bolt is not accessible from below. The top bolt can be accessed from the right side of the engine compartment after doing the following:
- unscrew the heat shields located near the power steering to access the exhaust manifold mounting nuts;
- unscrew the nuts and remove the rear section of the exhaust manifold from the cylinder head. Remove the gasket.
20. Note the location of the ground bus and the brackets fastened with the bolts of the gearbox to the engine.
21. After unscrewing the upper bolts securing the gearbox to the engine, raise the gearbox to its original position.
22. Remove the remaining two gearbox-to-engine bolts, then move the gearbox away from the engine so that the gearbox input shaft is removed from the clutch disc. When moving the gearbox, the gearbox input shaft must not hang on the clutch. When performing this work, be careful not to damage the clutch slave cylinder with hydraulic tube.
23. After the transmission input shaft has disengaged from the clutch, carefully lower the transmission and remove it from under the vehicle.
Installation
1. Check and, if necessary, center the clutch disc.
2. Before installing the gearbox, check the presence of lubrication on the clutch release mechanism.
3. Check the condition of the bearing at the end of the crankshaft.
4. Lubricate the transmission input shaft splines with a thin coat of molybdenum disulphide grease.
5. Place the gearbox on a jack through a wooden beam and lift it into place.
6. When lifting the gearbox, check that the clutch slave cylinder with the hydraulic tube are not pinched between the gearbox and the vehicle body.
7. Move the gearbox towards the engine, while the input shaft of the gearbox should fit into the grooves of the clutch disc. It may be necessary to rotate the engine crankshaft slightly to align the transmission input shaft splines with the clutch disc splines. When installing the gearbox, the input shaft must not hang on the clutch disc.
8. Move the gearbox forward so that the clutch housing rests on the engine block. If necessary, turn the gearbox so that the holes for the gearbox mounting bolts line up with the holes in the engine.
9. Secure the gearbox with bolts. At the same time, check that the ground bus and the brackets that secure the same bolts are in place.
10. Further installation is carried out in the reverse order of removal, taking into account the following points.
11. If necessary, install the exhaust manifold with a new gasket.
12. If necessary, bleed the hydraulic clutch system.
13. Connect the propeller shaft to the gearbox output flange.
14. Install the exhaust system.
15. Pour oil into the gearbox.