Withdrawal
The gearbox is removed downwards from the engine compartment after disconnecting from the engine. Use an appropriate lift to support the weight of the gearbox. Use a winch to support the weight of the engine when removing the gearbox. Remove the negative terminal from the battery. Remove the hood.
Remove the air filter and elements of the air supply system to the engine. Remove the clutch cable from the clutch release lever.
Disconnect the connector from the reversing light switch on the transmission.
Unscrew the upper gearbox-to-engine bolts, ground rails, and hose clamps (see fig. 7A.27).
Unscrew the bolt securing the ground bar to the top of the gearbox.
Disconnect the connector from the vehicle speed sensor. Disconnect the connector from the oxygen sensor.
Unscrew and remove the upper starter mounting bolt.
Raise the front of the car and secure it on stands. Remove the front wheels. On both sides of the car, unscrew the nuts and disconnect the anti-roll bar from the levers. Unscrew the nuts securing the ball joints of the steering rods to the steering knuckles. Remove the ball joints from the steering knuckles. Unscrew fastening and remove cross-section levers. When removing the ball joints, be careful not to damage the protective rubber boot.
Install a suitable container under the gearbox and, by unscrewing the drain plug, drain the oil from the gearbox. Screw the drain plug back into place.
Remove the right drive shaft from the gearbox. To do this, insert between the inner hinge of equal angular velocities (SHRUS) and the crankcase with a pry bar or screwdriver, and while the assistant will forcefully pull the wheel of the car outward, with a strong sharp blow to the end of the pry bar, dislodge the drive shaft from the differential side gear.
Using a soft wire, hang the inner end of the drive shaft from the tie rod.
Remove the left drive shaft from the gearbox in the same way.
Unscrew bolts and disconnect the catalyst from a back part of an exhaust system.
Unscrew 2 nuts and disconnect a receiving exhaust pipe from a collector. Remove the catalyst.
Remove the starter.
Unscrew the clamping bolt securing the shift rod to the shift shaft on the rear of the box.
Mark the position of the front and rear sections of the shift rod, unscrew the clamp bolt and remove the rod from the shaft at the rear of the gearbox.
Remove the bolt and disconnect the shift support link from the suspension at the rear of the transmission.
Position a jack under the engine and raise it just enough so that the weight of the engine is supported by the jack.
Unscrew bolts and disconnect a forward left suspension bracket from a body.
Disconnect the connector from the crankshaft angle sensor and unscrew the air pulsation filter housing (see fig. 7A.28).
Disconnect the speedometer cable from the vehicle speed sensor.
Unscrew bolts of fastening of the left back suspension bracket of the power unit.
Lower the engine together with the gearbox, unscrew the 6 bolts securing the left suspension brackets to the gearbox. Remove both pendants (see fig. 7A.29).
Recheck that the engine is securely supported by the jack.
Unscrew the remaining bolts securing the gearbox flange to the engine (see fig. 7A.30).
Slightly lift the gearbox by hand, move it away from the engine until the splines of the driven disc hub disengage from the input shaft, then lower and remove the gearbox from under the engine.
Installation
Installation is carried out in the reverse order of removal, taking into account the following points:
- check that the mating surfaces are clean;
- lubricate the splined part of the input shaft of the gearbox and the guide sleeve of the release bearing with a thin even layer of special grease;
- when installing the drive shafts in the gearbox, use new circlips;
- check that the suspension of the power unit has become in place, and pre-tighten the mounting bolts. Lower the power unit completely and finally tighten the bolts;
- reinstall the transverse levers and connect the steering rods;
- when connecting the catalyst to the exhaust system, use a new gasket;
- connect and, if necessary, adjust the shift rod;
- fill the gearbox with oil.
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