Installation of a manual transmission

Before installing the gearbox, check the clutch and the clutch release bearing, see p. 86.

Thoroughly clean the inner splines of the clutch disc, the splines of the gearbox input shaft and the guide sleeve of the clutch release bearing.

Apply a light coat of Microlube GL-261 to the driveshaft spline and guide bushing. At the same time, grease all surfaces of the splines.

Caution: Do not over-lubricate, as excess lubricant will be thrown onto friction surfaces and impair clutch operation. Using a different lubricant can also cause clutch failure.

Check the clutch release bearing for ease of movement. If the bearing was noisy when the clutch was disengaged before removal, the bearing must be replaced.



Models up to 8/94: check that the clutch release lever -A- is correctly seated on the pivot bearing. Push the clutch release lever down. In this position, fix the lever with a wire or rubber band -B- so that its installation position does not change when installing the gearbox, C - gearbox input shaft.

Ensure that the intermediate plate is in the correct position before installing the gearbox. If necessary, fix the intermediate plate with a little grease.


Raise the gearbox with a garage jack to the correct position. Insert the gearbox input shaft into the splines of the clutch disc.

If, when installing the gearbox, the drive shaft does not fit into the splines of the clutch disc, have an assistant turn the engine crankshaft slightly by the V-belt pulley.

Align gearbox. In most cases, there are drive pins on the crankcase flange that must fit into the holes on the gearbox housing flange.

Finally, insert all mounting bolts and screw the gearbox to the engine. Tighten the fastening bolts to 45 Nm.

Attention: Under no circumstances should the gearbox be tightened to the engine by tightening the mounting bolts. First tighten all bolts uniformly and only then tighten with a torque wrench.

Insert bolts for intermediate plate and tighten to 10 Nm.

Gearbox MT-75

Carefully lower the garage jack and check if any part of the engine is touching the front wall, if necessary, support the engine from the front wall side with a block of wood.

Remove the welding electrode to hold the shift console in the installation position.

Insert the gear selector rod into the joint. Position shift console and tighten to 25 Nm.

Raise the gearbox with a garage jack.

Models up to 8/94. install clutch cable see p. 86.

Models from 9/94 connect the hydraulic line to the slave cylinder at the gearbox. To do this, insert a burr-free drill with a diameter of 9.5 mm into the connecting socket and insert the locking clip from the side. Remove the drill and connect the pipeline. In this case, the quick coupling should stop.


Install the starter see p. 167.

Connect the multi-pin connectors of the reversing light switch and the speed sensor.

Attach the gearbox crosshead and tighten the crosshead bolt to the gearbox to a torque of 70 Nm. Tighten bolts securing cross member to body to 40 Nm.

Gearbox N: Remove the plug from the hole in the extension of the gearbox and connect the propeller shaft to the splines of the input shaft. Fit propshaft to final drive flange and intermediate bearing and fasten by hand with bolts.

Attention: Do not forget to install washers at the intermediate support.

Gearbox MT-75, damper studs have studs

Check the condition of the rubber bridges -B- of the coupling on the propeller shaft. If the jumpers are cracked, then the cardan shaft assembly with the clutch must be replaced.

Attention. The cardan shaft is balanced as a clutch assembly and the parts of this assembly cannot be replaced individually. Cracks on the body of the coupling in the zone -C- do not matter, A is a metal sleeve.

Attach propshaft to final drive flange and fasten by hand with bolts. Slide the rubber shaft sleeve over the studs and fasten the shaft by hand with bolts at the intermediate support.

Attention: Do not forget to install washers at the intermediate support.

Screw on the nuts securing the rubber coupling and tighten to 80 Nm.

Attention: Check if the studs are firmly seated. If the studs loosen or turn when tightening the fastening, then the rubber sleeve fastening should be released again and the studs should be fastened properly.

To secure the studs, they must be unscrewed and the threads on the studs and in the damper cleaned.

Apply 2 drops of anti-twist Loctite 270 to the threads of the studs at a 180°arc.

Screw in the studs and tighten to 90 Nm.

Attention. Slotted studs must not be screwed into the damper instead of hex studs and vice versa.

Gearbox MT-75, damper studs have a hexagon

Tighten studs -A- for damper -B- to 120 Nm.

Attach propshaft to final drive flange and fasten by hand with bolts. Slide the rubber shaft sleeve over the studs and fasten the shaft by hand with bolts at the intermediate support.

Attention: Do not forget to install washers at the intermediate support.

Screw on the nuts securing the rubber coupling and tighten to 80 Nm.

Attention: Do not screw slotted studs into the damper instead of hexagonal studs and vice versa.

Tighten bolts for propshaft intermediate bearing to 20 Nm.

Tighten bolts for propshaft at rear axle to 65 Nm.

Vehicles with catalytic converter: Tighten the catalytic converter heat shield to the underbody.

Install exhaust system see p. 80.

Models up to 8/94: attach the stabilizer and tighten the clamps for fastening to the side members to a torque of 90 Nm.



Models from 9/94: Tighten the 2 screws securing the rear axle crossmember to 50 Nm. Also tighten the 4 bolts securing the crossmember under the gearbox/exhaust system to a torque of 40 Nm, see Fig. "Withdrawal".

Check and, if necessary, replenish the oil level in the gearbox, see p. 205.

Install the soundproofing cover in the engine compartment.

Lower the car.

Vehicles with V6 engine and diesel engine up to 8/94 sink mount the upper and lower parts of the radiator air duct.

Vehicles with a diesel engine in the engine compartment on the left and on the right clip the soundproofing cover.

Vehicles with V6 engine up to 8/94: Insert the rotor and install the distributor cap.

Gearbox N

Attach the gear lever to the gearbox extension and tighten the mounting bolts to 25 Nm.

Push the soundproofing cushion and the inner collar over the gear lever, insert into the 4 receiving holes to the locking position and secure with bolts.

Put the inner cuff on the frame.

Install the center console see p. 137.

Slip the outer boot over the shift lever and attach it to the console.

Screw the handle onto the gear lever.

Connect ground wire to battery (-).

If available, set the clock, enter the anti-theft code for the radio.

Gearbox MT-75

Change gears and check if they all turn on. If not all gears are engaged, check the position of the inner cuff and soundproofing cushion.

To check the position of the inner boot of the gear lever and the soundproofing cushion, unfasten from the side and remove the gear lever handle.

Remove center console see p. 137.



Loosen the outer boot -A- for the gear lever at the bottom and roll it up.

Remove the inner boot -B- of the gear lever together with the retaining frame and roll it up.

Check and, if necessary, correct the position of the sound insulation cushion -C-.

Slide the gear lever inner boot onto the retaining frame and secure the frame.

Pull the outer boot of the gear lever down and insert.

Install the center console see p. 137.