- elevated (compared to the usual) noise;
- difficult gear shifting;
- spontaneous disengagement or unclear engagement of gears;
- oil leakage through seals and gaskets.
In addition, the gearbox is removed to replace the clutch, flywheel and rear crankshaft oil seal of the engine.
An automatic transmission is removed for almost the same reasons as a manual transmission, except for the need to replace the clutch and flywheel, which are absent in this case. The methods for removing and installing manual and automatic transmissions are almost the same and are described using a manual transmission as an example. The difference lies in the design of the transmission control drive and the need to unscrew the torque converter mounting nuts.
Helpful tips:
- The work of removing and installing the gearbox is very labor-intensive, so first make sure that its malfunctions are not caused by other reasons (insufficient oil level, clutch drive defects, loose gearbox mounts, etc.).
- The gearbox is quite heavy and its shape is not convenient for holding, so we recommend removing the gearbox with an assistant.
You will need: keys "14", "18" and TORX E18, a screwdriver with a flat blade.
1. Remove the battery (see Removal and installation the battery).
2. Remove the battery mounting shelf (see Removal and installation the battery mounting shelf).
3. Remove the front wheel drives (see Removal and installation front wheel drives).
4. Remove the starter (see Removal and installation the starter).
5. Disconnect the wiring harness connector from the reverse gear sensor.
6. Remove the retainer and disconnect the hose tip from the clutch release hydraulic drive intermediate pipe adapter.
7. Remove the clutch release hydraulic drive line from the holder on the body bracket and move it to the side.
8. Disconnect the wire harness holders from the transmission brackets and move the harness to the side.
9. Use a screwdriver to pry up the tip of the gear shift cable…
10. …and disconnect the cable end from the gearbox lever, overcoming the elastic resistance of its spring retainer.
11. Use a screwdriver to pry up the tip of the gear selection cable…
12. …and disconnect it from the gearbox lever, overcoming the elastic resistance of the spring retainer.
13. Move the gear selector cable housing stop lock back…
14. …and remove the stop from the bracket on the gearbox.
15. Similarly, disconnect the gear selection cable stop from the bracket.
16. Attach the lifting gear slings to the front and rear transport eyes of the power unit and tighten the slings.
17. Remove the left powertrain suspension support (see Replacing the left support of the powertrain suspension).
18. Remove the front suspension subframe (see Removal and installation the front suspension subframe).
19. Install a support under the gearbox and engine housings.
20. Unscrew the two upper bolts securing the gearbox to the engine cylinder block on the right…
21. …and on the left.
22. Unscrew the three bolts securing the front powertrain suspension bracket to the gearbox and remove the bracket.
23. Remove the three bolts securing the clutch oil pan to the engine oil pan.
24. Move the gearbox as far back as possible (the primary shaft must disengage from the clutch driven disk hub), remove the support from underneath it and remove the gearbox from the car.
Caution! When removing the gearbox, do not rest the end of the input shaft against the diaphragm spring petals to avoid deforming them.
25. Install the gearbox and all removed parts and assemblies in the reverse order of removal.
Helpful tips:
- Before installing the gearbox, we recommend lubricating the splines of the input shaft with a thin layer of high-melting consistent grease.
- Check the alignment of the clutch driven disc using a special mandrel (see Removal and installation the clutch).
- Before connecting the front wheel drives to the gearbox, replace the retaining rings on the splined tails of the inner joints with new ones. Otherwise, there is a risk of disconnecting the drives from the gearbox while driving.
26. Fill the gearbox with oil (see Checking the level, topping up and replacing oil in a manual gearbox and working fluid in an automatic gearbox).
27. If necessary, adjust the gearbox control drive (see Adjusting the gearbox control drive).
28. Pour the working fluid into the reservoir of the master brake cylinder (in its section intended for supplying the hydraulic clutch release drive) and remove air from the clutch release hydraulic drive (see Bleeding the clutch release hydraulic drive).
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