Removing the manual transmission is carried out without removing the engine, through the bottom of the car. Removing the manual transmission is necessary when the clutch is removed or the manual transmission is to be replaced or repaired.
Removing manual transmission type «S5D 280Z» must be done in the following order. Prepare fixtures «00.2.030», «23.0.130», «23.0.131», «23.0.132» And «23.0.133».
Attention!
- When the negative terminal of the battery is disconnected, the data in the ECU-KSUD is erased. Before starting work, read the information from the memory of the engine management system and fix it.
- When removing and installing the manual transmission, it should not rest on the input shaft, otherwise the clutch disc will be deformed.
Remove power by removing the key from the ignition and disconnect «–» terminal AB. Remove connection jumper «masses» with body. Remove the intermediate muffler, right front and rear heat shields.
Remove the stiffening plate, front and rear crankcase protection panels and drain the oil from the manual transmission. Loosen the anti-roll bar and move it forward. Remove the front propeller shaft, unscrew the bolts and remove the clamp (1, fig. 8.4) fastening of the exhaust pipe.
Mark the relative position of the engine and manual transmission with paint or a marker to facilitate their subsequent assembly. Mark bolts, as they have different lengths. Remove the three bottom bolts «Torx» mounts (M8x50) Manual transmission to the engine (see fig. 8.7).
Assemble fixture «23.0.130, together with devices «00.2.030» And «23.0.130» (pic. 8.5), support them with manual transmission and transfer case (RK). Remove the cable harness from the mounting brackets on the gearbox housing. Loosen the fixing screws (6, see fig. 8.3), detach the support beam (1) from the body. When disconnecting the rubber-metal joint (3), turn only the nut (5), while holding the head of the bolt (4, M12x1.5x220).
Attention! Do not allow the cardan shaft to fall, due to the possibility of damage to the hinges and the rubber boot of the CV joint.
Loosen the bolts (3 pcs., arrows, see fig. 10.5) fastening the universal joint, while holding the head of the bolt and turning the nut. While holding the cardan shaft, unscrew the nuts securing its intermediate support to the body. Bend the cardan shaft down by pressing the intermediate support down and disconnect the shaft from the flange of the secondary (weekend) shaft of the manual transmission, take it to the side and fix it on the body with a wire bracket, preventing it from breaking in the hinge, in order to avoid damage to the CV joint.
Attention! Make sure that the exhaust manifold does not come into contact with the anti-roll bar.
Slightly lower the manual transmission, for further work. Without touching the clutch pedal anymore, unscrew the fastening nuts (18, see fig. 7.2), remove the clutch slave cylinder and secure it to the body with a wire clamp. Leave the hydraulic line connected. Do not touch the clutch pedal again.
Disconnect the loop from the switch (8, see fig. 8.31) reversing lamp and remove the wiring harness from the holders on the gearbox housing.
Remove retaining clip (11, see fig. 8.16) thrust (10) gear shift actuator, remove the rod (10) from the clip (12) and remove the mounting washers.
Loosen the spring clip with a screwdriver (1, fig. 8.6) and unhook it from the tide (2) on the crankcase. Pull out the spring clip (1) up and remove the hinge pins (3 and 4, see fig. 8.16). Install a garage jack through a wooden gasket under the engine, in the area of the first cylinder, in order to prevent it from tipping over at the time of removing the manual transmission.
Attention! When removing and installing the manual transmission, exclude hanging of the manual transmission on the primary (input) shaft, otherwise the clutch disc may be deformed.
Loosen, crosswise, the remaining bolts (arrows, fig. 8.7) fixing the manual transmission to the engine and unscrew them completely. In this case, the manual transmission relies only on the assembly of devices.
Together, with an assistant, disconnect the engine and manual transmission, moving it back, remove the box, turn it as far as possible (about 10°), counterclockwise, and remove the manual transmission from under the vehicle.
The installation of the manual transmission should be carried out in the reverse order, while it is necessary to check the technical condition of the clutch and make sure that the clutch release bearing rotates easily and lubricate it with grease type «Molykote-Longtherm-2».
Check the driven disk for rust in the splines and replace if necessary. Use a rag to remove old grease and dust from the splines of the driven disk, resulting from abrasion of the friction lining.
Attention! Bearing only wipe, but do not wash. The bearing should not make any noise during rotation.
Check the installation of the centering sleeves (18, see fig. 8.31) on the gearbox housing. Check the installation of the clutch basket on the flywheel. Remove the clutch and release fork, clean them and lubricate them in their respective places. Check for sticky grease on the primary (input) gearbox shaft. If the grease is sticky, replace the clutch disc.
Clean and lubricate the splines and journal of the input shaft of the manual transmission with a thin layer (pic. 8.8) type anti-friction paste «Microlude GL 261» or apply an anti-friction spray such as «Esso UNIREX 52». The amount of lubricant is appropriate to the size of a pea, so that excess lubricant cannot get on the friction surface of the clutch and interfere with its operation.
Engage one of the forward gears in the manual transmission, raise it and, in a suspended position, put it into the clutch.
Attention! If, during installation, the input shaft of the gearbox does not fit into the splines of the clutch driven disk, then turn the output shaft by the flange of the driveshaft installation by hand until the splines match.
Screw in the manual transmission mounting bolts, together with washers, and preliminarily, according to the principle through one, tighten with a torque of 2.0 kgf·m. Further tightening should be carried out crosswise, with the final torque indicated below.
Bolt tightening torques (nuts) fasteners, N·m (kgf·m):
- bolt type «Torx»:
- m8 22 (2,2);
- m10 43 (4,3);
- m12 72 (7,2).
- hex bolt:
- m8 25 (2,5);
- m10 49 (4,9);
- m12 74 (7,4).
- nut of fastening of the working cylinder - 22 (2,2);
- intermediate support nut - 21 (2,1);
- CV joint nut, flat/knurled head:
- M8 32 (3,2) / 43 (4,3);
- M10 64 (6,4) / 70 (7,0).
- bolts transverse to the body - 49 (4,9);
- fastening nuts are transverse to the manual transmission - 74 (7,4);
- clamp fastening nuts (M8) – 15 (1,5);
- flexible coupling of the cardan shaft - 100 (10,0);
- (replace self-locking nuts)
- filler and drain plugs - 50 (5,0).
Tighten the stiffening plate mounting bolts in two steps - 56 Nm (5.6 kgf·m) + 90°.
Contact switch for reversing lights (M12) – 18 (1,8);
Install anti-roll bar and secure with new self-locking nuts, tightening torque 60 Nm (6.0 kgf·m).
When installing the removed parts, it is forbidden to apply significant efforts so that the parts are not subjected to excessive mechanical stress. Install clip (12, see fig. 8.16) shift rod. Lubricate the traction (10) gear shift grease type «Kluber Polylub DLY 801» and install traction (with washers and retaining clips, 11) in place. Pour oil into the manual transmission and check its level.
Reinstall all removed elements and, if necessary, adjust the gearshift mechanism.
When replacing the S5D 280Z manual transmission from the old to the new one, the following parts should be rearranged to the new manual transmission:
- release bearing and clutch release fork;
- studs for fastening the clutch slave cylinder;
- reversing light switch;
- holder of the gear selection rod;
- check damping washer (14, see fig. 8.16) in the rod holder for damage and, if necessary, replace it;
- breather (14) and a safety sleeve from the gear selector rod.
Gearbox S5D 39Z complete with engine «M57» and fixed to the body with a beam (1, see fig. 8.3) and rubber-metal joint (3), similar to manual transmission S5D 280Z. Manual transmissions differ only in their reinforced design, tk. carry different loads due to the increased torque of the M57 engine transmitted to the wheels of the car. Removal and installation of manual transmission S5D 39Z should be carried out in the same manner as manual transmission S5D 280Z.