Removal and installation of a manual transmission.
1 - gearbox bracket, 2 - power unit front support, 3 - gearbox assembly, 4 - power unit rear support.
Gear selection and shift mechanism.
1 - transmission control cables, 2 - gear lever handle, 3 - gear lever, 4 - housing, 5 - bracket.
Withdrawal
1. Disconnect the cable from the negative battery terminal.
2. Remove the air filter duct.
3. Remove the air filter assembly and engine intake duct.
4. Disconnect the reversing light switch connector.
5. Remove the clutch slave cylinder (see chapter "Clutch").
6. Disconnect the speedometer drive cable.
7. Remove shift cable and gear select cable (see section "Gearbox control cables").
8. Turn away bolts of fastening of a starter and the top bolts of fastening of a transmission.
9. Using the special tool, hang out the engine as shown in the figure.
10. Remove the gearbox bracket assembly.
11. Raise the car on the lift.
12. Turn away bolts and remove forward wheels.
- Tightening torque: 90-110 Nm
13. Drain the oil from the gearbox housing (see chapter "Maintenance and general inspection and adjustment procedures").
14. Disconnect the tie rod ends, lower ball joints and drive shafts (see chapter "Drive shafts").
15. Disconnect the intermediate steering shaft, unscrew the bolt securing the return pipe of the working fluid of the power steering pump (see chapter "Steering").
16. Disconnect the elements of the exhaust system (see chapter "Exhaust system").
17. Turn away bolts of fastening of a subframe and remove a subframe.
18. Turn away bolts and remove forward and back support of the power unit.
- Tightening torque: 60-80 Nm
19. Turn away lateral bolts of fastening of a transmission.
20. Lower the transmission assembly from the engine compartment, supporting it with a rolling hydraulic jack.
Note: When supporting the gearbox, make sure that the contact between the crankcase and the jack is superficial and not pinpoint.
Installation
1. The gearbox is installed in the reverse order of removal, the tightening torques of the bolts and nuts are indicated in the text of the description of the removal procedure and in the assembly drawing "Removal and installation of a manual transmission".
2. Installation of brackets and supports is carried out in the following order:
- engine bracket,
- gearbox bracket,
- rear support of the power unit,
- front support of the power unit.
3. When assembling the gearbox, use the following lubricants and sealants.
Lubricants:
- for input shaft splines: CASMOLY L9508
- for gland lip: RETINAX AM, MOLYTEX GREASE EP-2
Sealants:
- for mating planes of the gearbox, clutch housing and rear cover: gearbox THREE BOND 1216
- bolts (with collar) bearing support: THREE BOND 1303