- disconnect «negative» battery terminal;
- in the cab of the car, lift the protective cover of the gear lever, unscrew the lever at the bottom and remove it together with the cover;
- raise the front of the car with a jack and place it on supports;
- drain gear oil (see below);
Pic. 186. Safety bracket propeller shaft
- unscrew the safety bracket for fastening the cardan shaft, shown in fig. 186;
Pic. 187. Fastening the cardan shaft to the gearbox
- Disconnect propeller shaft from gearbox. When unscrewing the nuts with a head, hold the bolt heads with a box wrench. The shaft can be rotated to get access to all the bolts. The fastening of the cardan shaft is shown in fig. 187;
- unscrew the intermediate support of the cardan shaft, as well as the fastenings of the parking brake cable located nearby. Pull out the cardan shaft and hang it on a wire loop to the bottom of the car in a suitable place. Under no circumstances should the cardan shaft be left unbound;
- insert wood block (size 90x20x30 mm) between the engine crankcase and the transverse beam so that the engine does not move from the supports when the gearbox is removed;
Pic. 188. Fixing the box support in the center of the traverse
Pic. 189. Fastening the rear traverse of the gearbox to the spars
- remove the engine rear yoke by first unscrewing the connection shown in fig. 188, and then shown by arrows in fig. 189 crosshead mounting bolts;
- unscrew the clutch slave cylinder from the gearbox without removing the hydraulic hoses. Remove the gasket installed between the cylinder and the gearbox;
Pic. 190. Speedometer impulse sensor connector
- disconnect all electrical wires suitable for the gearbox, as well as the plugs of the reverse signal switch and the speedometer sensor. The fastening of the latter is shown in fig. 190. To remove, unscrew the internal hex bolt;
- place a jack under the gearbox. It must be the right height. It is possible to place a block of wood on the lifting rod of the jack to support the gearbox. Raise the gearbox with a jack and unscrew the fastening bolts between the engine and the gearbox. Disconnect also the wire «masses»;
- carefully pull the gearbox back and then lower the jack. At the same time, make sure that the clutch shaft comes out of the splines of the driven disk in order to avoid deformation of the shaft or damage to the disk.
Warning! Be sure to do the work with an assistant - he must hold the gearbox when lowering the jack. Caution: risk of injury!
Before reinstalling the gearbox, it is necessary to check the condition of the clutch: how many miles it has passed, whether it worked properly, etc.
The gearbox must be installed in the reverse order, taking into account the following instructions:
- apply a little grease to the splines of the clutch drive shaft;
- raise the gearbox with a jack and insert the shaft into the hole in the hub of the driven disk. Turn the shaft flange slightly if necessary. Slide the gearbox towards the engine. The mounting sleeves on the engine must clearly fit into the holes in the gearbox housing;
- bolt the gearbox housing to the engine with a torque of 55 Nm. Tighten the wire with the same torque «masses»;
- install a traverse «make money» the gearbox support mounting bolt in the middle and tighten the bolts on both sides of the traverse to 45 Nm. Tighten the support mounting bolt and nut to 90 Nm. Take out the wooden block;
- insert the speedometer impulse sensor plug and tighten the fastening bolt to 8 Nm (see fig. 190);
- plug in reverse signal plug;
- install the working cylinder with a gasket and evenly tighten the two fastening bolts to a torque of 25 Nm;
- install the cardan shaft on the gearbox flange, evenly tighten the bolts in a circle to a torque of 60–65 Nm;
Pic. 191. Fastening of the intermediate support of the cardan shaft: 1 - safety bracket; 2 - parking brake cable holder
- install the propshaft intermediate support (pic. 191). Install parts 1 and 2 accordingly and tighten the bolts to a torque of 85–90 Nm. Tighten the propeller shaft safety bracket bolts to the same torque (see fig. 186);
- Apply high temperature grease to the gear lever seat cone and secure it in the shift mechanism. Screw in the bolt and tighten to 65 Nm. Put on the protective cover of the lever and fix it;
- to plug «negative» battery terminal;
- fill with gear oil. If it did not drain, check its level and, if necessary, bring it to normal;
- if a radio with security coding is installed, enter the code, set the time.