Installation of a manual gearbox (Scorpio 2)

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

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

Apply a thin layer of special Microlube GL-261 grease to the splined connection of the drive shaft and the guide sleeve. Lubricate all surfaces of the splines.

Caution: Do not apply too much grease, as excess grease will be thrown onto the friction surfaces and will cause the clutch to malfunction. Using other grease may also cause the clutch to malfunction.

Check the clutch release bearing for ease of movement. If noise was emitted from the bearing when disengaging the clutch 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 support. Press the clutch release lever down. In this position, secure the lever with wire or rubber band "B" so that its mounting position does not change when installing the gearbox, C - gearbox drive shaft.



Before installing the gearbox, ensure the correct position of the intermediate plate. If necessary, fix the intermediate plate with a small amount of grease.

Using a garage jack, move the gearbox to the correct position. Insert the drive shaft of the gearbox into the splines of the driven clutch disc.

If, when installing the gearbox, the drive shaft does not enter the splines of the driven clutch disc, ask an assistant to turn the engine crankshaft slightly by the V-belt pulley.

Align the gearbox. In most cases, there are guide pins on the engine case flange that should fit into the holes in the gearbox housing flange.

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

Caution: Do not under any circumstances tighten the gearbox to the engine by tightening the mounting bolts. First, tighten all the bolts evenly and only then tighten them with a torque wrench.

Screw in the intermediate plate mounting bolts and tighten to a torque of 10 Nm.

Gearbox MT-75

Carefully lower the garage jack and check that no part of the engine is touching the front wall; if necessary, support the engine from the front wall with a wooden block.

Remove the welding rod to hold the shift console in the mounting position.

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

Raise the gearbox with a garage jack.

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

Models with 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 nipple and insert a locking bracket from the side. Remove the drill and connect the line. The quick-release coupling should lock.



Install the starter, see p. 167.

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

Attach the gearbox crossmember and tighten the crossmember mounting bolt to the gearbox to a torque of 70 Nm. Tighten the crossmember mounting bolts to the body to a torque of 40 Nm.

Gearbox N: Remove the plug from the hole in the gearbox extension and connect the cardan shaft to the splines of the drive shaft. Place the cardan shaft against the flange of the main gear and the intermediate support and secure it by hand with bolts.

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

Gearbox MT-75, damper studs have sprockets

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

Attention. The cardan shaft is balanced together with the coupling and the parts of this unit cannot be replaced separately. Cracks on the coupling body in the "C" zone are not important, A is a metal bushing.

Place the cardan shaft against the main transmission flange and secure it by hand with bolts. Slide the shaft rubber coupling onto the studs and secure the shaft by hand with bolts at the intermediate support.

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

Screw on the rubber coupling mounting nuts and tighten to a torque of 80 Nm.

Caution: Check that the studs are securely seated. If the studs are loose or turn when tightened, the rubber sleeve mount should be loosened again and the studs should be tightened properly.

To secure the studs, you need to unscrew them and clean the threads on the studs and in the damper.

Apply 2 drops of Loctite 270 anti-loosening agent to the stud threads in an arc of 180°.

Screw in the studs and tighten to a torque of 90 Nm.

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

Gearbox MT-75, damper studs have a hexagon

Tighten studs "A" of damper "B" to a torque of 120 Nm.

Place the cardan shaft against the main transmission flange and secure it by hand with bolts. Slide the shaft rubber coupling onto the studs and secure the shaft by hand with bolts at the intermediate support.

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

Screw on the rubber coupling mounting nuts and tighten to a torque of 80 Nm.

Caution: Do not screw splined studs into the damper instead of hexagonal studs and vice versa.

Tighten the intermediate support bolts of the propeller shaft to a torque of 20 Nm.

Tighten the propeller shaft mounting bolts at the rear axle to a torque of 65 Nm.

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

Install the exhaust system, see p. 80.

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



Models from 9/94: Tighten the 2 rear axle cross member mounting bolts to 50 Nm. Also tighten the 4 cross member mounting bolts under the gearbox/exhaust system to 40 Nm, see. "Removal".

Check and top up the gearbox oil level if necessary, see p. 205.

Secure the soundproofing material to the engine compartment.

Lower the car.

V6 and diesel vehicles up to 8/94 sink the upper and lower radiator duct mounts.

For vehicles with a diesel engine, secure the sound-insulating material with clamps in the engine compartment on the left and right.

V6 vehicles prior to 8/94: Insert rotor and install distributor cap.

Gearbox N

Place the gearshift lever against the gearbox extension and tighten the mounting bolts to 25 Nm.

Place the sound-insulating pad and inner cuff through the gear shift lever, insert into the 4 receiving holes until it locks into place and secure with bolts.

Place the inner cuff on the frame.

Install the center console, see p. 137.

Place the outer sleeve over the gear shift lever and secure it to the console.

Screw the handle onto the gear shift lever.

Connect the ground (-) cable to the battery.

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

Gearbox MT-75

Shift gears and check if all of them engage. If not all of the gears engage, check the position of the inner cuff and sound-insulating cushion.

To check the position of the inner gear shift lever boot and sound insulating cushion, unfasten the gear shift lever handle from the side and remove it.

Remove the center console, see p. 137.



Unfasten the outer sleeve "A" of the gear shift lever at the bottom and roll it up.

Remove the inner cuff "B" of the gear shift lever together with the retaining frame and roll it up.



Check and, if necessary, adjust the position of the sound-insulating cushion "C".

Place the inner gear shift lever sleeve onto the retaining frame and secure the frame.

Pull the outer cuff of the gear shift lever down and insert it.

Install the center console, see p. 137.