Vehicles with engines 111.948 and 601.970
Removing
1. Disconnect the negative cable from the battery.
2. Remove the front wheels.
3. Remove bracket 4 for wiring (see fig.6.8a).
Pic. 6.8a. Removal and installation of a transmission (vehicles with engines 111.948 and 601.970):
1. Clips,
2. Gearshift cables,
3. Lifting device,
4. Wiring bracket,
S19. reversing light switch,
S19.1. Reversing light switch wiring connector.
4. Disconnect wiring connector S19.1 from reversing light switch.
5. Disconnect cables of a gear change 2 from a transmission.
6. Unscrew the starter and remove it without disconnecting the electrical wiring from it.
7. Insert the lifting device 3 on the engine and remove the transmission mounts (on vehicles with diesel engines, remove the power steering reservoir).
8. Remove the lower engine protection.
9. Disconnect the left axle shaft 5 from the flange (see fig. 6.8 b).
Pic. 6.8 b. Removal and installation of the gearbox:
5. Left half shaft,
6, 7, 9, 10. Bolts,
8. Trailing arm,
11. Bracket,
12. Intermediate shaft,
13. Spring pin,
14. Right half shaft,
15. Clutch slave cylinder,
G3. Vehicle speed sensor.
10. Disconnect the left tie rod from the subframe.
11. Remove the clutch slave cylinder 15 without disconnecting the hydraulic line, and fix it on the side.
12. Remove the G3 speed sensor. Replace seal.
13. Turn off a bolt 9 fastenings of the case of a transmission. The gearbox must be lifted with a lifting device 3 so that the bolt 9 can be removed in a straight line and also inserted.
14. Disconnect the trailing arm 8 from the subframe.
15. Remove intermediate shaft with bearing 12.
16. Install the gearbox on the lift.
17. Turn off bolts 10 fastenings of a transmission and remove it.
18. Remove the left gearbox flange (only if the gearbox is to be replaced).
Installation
19. Installation is made in an order, the return to removal. When removing and installing the gearbox, make sure that its components are not damaged. The mounting clamp must be installed before connecting the injection tube. Check the clutch and, if necessary, replace it. Check the oil level in the gearbox and, if necessary, adjust it.
Vehicles with engine 611.980
Removing
20. Disconnect the negative cable from the battery.
21. Remove the front wheels.
22. Drain the gearbox oil.
23. Disconnect half shafts from a transmission.
24. Disconnect the electrical wiring from the gearbox.
25. Unscrew the nut securing the wires in the junction box.
26. Disconnect the junction box from the washer reservoir.
27. Disconnect the shift cables from the gearbox.
28. Disconnect the pressure pipeline from the clutch release assembly.
29. Turn off a nut of a collar of fastening of the loading pipeline from a transmission.
30. Unscrew the central shaft from the gearbox and remove it.
31. Disconnect the left fork 7 in the area of the longitudinal beam 3 from the subframe until the rubber bush 8 is disconnected from the pivot (see fig.6.9).
Pic. 6.9. Removal and installation of a transmission (vehicles with engine 611.980):
1. Clutch,
2, 4, 5, 6, 8. Bolts,
3. Longitudinal beam,
7. Fork.
9. Lifting device.
32. Turn off an arm of a reservoir of the amplifier of a steering.
33. Disconnect the tube from the left washer sprayer.
34. Insert the lifting device, attach it to the engine brackets and tighten it slightly.
35. Turn off a bolt 5 fastenings of a transmission.
36. Lower the engine using a lifting device. When lowering, be careful not to damage the steering hydraulic lines between the subframe and the pan.
37. Remove the exhaust manifold along with the catalyst.
38. Turn off bolts 2 fastenings of the case of a transmission.
39. Remove gearbox 1.
40. Disconnect the left gearbox flange (only if the gearbox is to be replaced).
Installation
41. Installation is made in the reverse order of removal. The mounting clamp must be installed before connecting the injection tube.