Note. This is a very difficult job. Before starting, carefully study the entire procedure and purchase a suitable winch or pallet truck.
Withdrawal
1. Disconnect the wire from the negative battery terminal (see chapter 5A).
2. Raise the vehicle and place it on stands (cm. "Lifting and placing the car on supports"). Make sure. that the vehicle has been raised to such a height that it is possible to remove the gearbox from under the vehicle. Turn out screws and remove protection of a crankcase of the engine and a transmission.
3. Remove the starter (see chapter 5A).
4. On models with a four-cylinder M43TU engine, unscrew the nuts, remove the ignition coil and move it to the side. This is to prevent damage to the high voltage ignition circuit when the engine is moved. It is not necessary to disconnect high voltage wires.
5. Remove cardan shaft (see chapter 8).
6. Under the car take out a clamp of an axis of draft of a gear change. Take out an axis and remove washers. Similarly, remove the axle from the gear lever and remove the link (fig 7.6).
7. Turn away nuts of fastening of the working cylinder of coupling to a transmission and remove the working cylinder from hairpins. Secure the cylinder to the side, taking care not to pull on the hose.
8. Note the location of all electrical wiring connectors and disconnect them Unhook all wiring harnesses from the gearbox.
9. Disconnect from a transmission a basic arm of an exhaust system.
10. Turn out bolts of fastening and remove the amplifier of a forward suspension bracket.
11. In models with a six-cylinder engine, remove the air duct for the interior heating / ventilation system from the rear of the engine compartment as follows (pic. 7.11, a, b).
- A) Remove the cabin air filter cover by turning its retainers 90°counterclockwise. Pull the filter out of the housing.
- b) Unfasten the four latches of the wiring box and remove the sleeves with wires from the box.
- V) Remove the four screws and pull the cabin filter housing forward.
- G) In the left rear corner of the engine compartment, pull off the seal, turn the two latches counterclockwise and slide the trim panel slightly forward.
- d) Turn out two screws and remove an air duct.
- e) Release from clips and remove a casing of an air duct from the forward cross panel.
12. On models with the M43TU four-cylinder engine, support the engine with a hydraulic trolley jack. Place a jack under the engine sump by placing a block of wood between the jack and the sump. Raise the jack until it just touches the pallet.
13. On other models, attach a winch to the engine rigging eye. The lug is located on the rear left corner of the engine (at the rear of the cylinder block).
14. Place a pallet truck under the gearbox (behind the clutch cover). Place a piece of wood on top of the cart, then lift the cart up to hang out the gearbox.
15. Remove the subframe and mountings of the rear transmission support.
16. Using a jack (or winches) lower the engine and transmission so that the engine exhaust manifold passes under the bulkhead of the engine compartment. Make sure. that at the same time the engine did not hang on any hoses or wires passing along the engine bulkhead.
17. At the top of the gearbox, remove the gear lever pin retainer. Remove the pin and disconnect the lever from the gearbox (pic. 7.17).
18. Remove the bolt securing the gearbox/engine adapter to the right side of the clutch housing and/or remove the lower part of the flywheel housing (depending on the model) (pic. 7.18).
19. Turn out bolts of fastening of a transmission to the engine, remove washers, then shift a transmission back and disconnect a primary shaft from coupling. During this operation, be very careful not to hang the gearbox on the input shaft. After the gearbox is disconnected from the engine, make sure that the heater hoses are not kinked.
20. Lower the transmission and roll it out from under the vehicle. If the transmission has been removed indefinitely, make sure the engine is securely supported.
Installation
21. Before installation, center the clutch disc (see chapter 6)
22. Before installing the gearbox, check the condition and lubricate the release bearing and fork (see chapter 6).
23. The rest of the installation procedure is performed in the reverse order of removal. Pay attention to the following points.
- A) Check for gearbox dowel pins (they are located at the rear of the engine).
- b) Don't forget to put washers on the gearbox-to-engine bolts.
- V) Tighten all fasteners to the required torque.
- G) Lightly lubricate the shift lever shaft and link shaft before installation.
- d) Connect the propeller shaft to the gearbox (see chapter 8).
- e) Install starter (see chapter 5A).