Note. If the gearbox is replaced, the items listed below must be replaced.
Clutch drive fitting.
Engine damping block bracket.
Shift cable bracket.
Rear gearbox bracket.
Removing
Remove the lower engine compartment cover, if installed.
Remove the center muffler and front exhaust pipe.
Attach KM 6001-A to the front axle housing.
Loosen 2 bolts (arrows) guides on KM-6001-A.
Install KM-6001-A as shown in the figure.
Note. The 2 journals must be in the holes in the guide of the front axle housing.
Tighten the 2 adjustment rail bolts.
Rotate the front support bearing until it contacts the drive pin of the front engine damping block.
Note. The guide pins must be located in the thrust bearings without play.
Rotate the rear support bearing until it contacts the drive pin of the engine damping block rear bracket.
Note. The guide pins must be located in the thrust bearings without play.
Remove the front axle housing.
Remove the air filter housing with the air intake hose.
Disconnect the harness connector (4), reversing light switch.
Close the brake fluid reservoir.
Fill the reservoir of the hydraulic drive of the brake system to the mark «MAX».
Disconnect the pressure pipeline with the union.
Note. Place a pan underneath to drain the brake fluid.
Unlock the retaining clamp with a screwdriver and disconnect from the discharge pipeline.
Bend the retaining yoke slightly and reinstall on the fitting.
Disconnect the left engine damping block.
Disconnect from left engine damping block bracket.
Loosen 3 mounting bolts.
Disconnect the top of the gearbox from the engine by unscrewing the 4 mounting bolts (arrows in the picture).
Note. If necessary, pull the cooling system piping up and secure with cable ties.
Attention! Be careful not to damage the wiring harnesses and fasteners.
Lower the engine and gearbox approximately 5 cm using the special tool MKM-883-1.
Remove the wheel shafts from the gearbox.
Place a sump underneath to drain the gear oil.
Note. The wheel shafts remain in the wheel hubs.
Attach the wheel shafts to the bottom of the car.
Close the openings of the wheel shafts with plugs.
Disconnect the front damping block of the engine from the gearbox by unscrewing the 2 mounting bolts.
Disconnect the gearbox from the pallet by unscrewing the 3 mounting bolts.
Disconnect the front and rear of the gearbox from the engine by unscrewing the 2 mounting bolts.
Attention! Be careful not to damage the wiring harnesses and fasteners.
Remove the gearbox.
Move the gearbox away from the engine block and carefully lower it.
Installation
Attach the gearbox to the engine.
Make sure the installation is correct.
Raise and center the gearbox.
Attach the front and rear of the gearbox to the engine and tighten the 2 mounting bolts to 60 Nm.
Establish the pallet of a transmission and tighten 3 bolts of fastening the moment of 40 Нм.
Attach the engine front damping block to the gearbox and tighten the 2 mounting bolts to 80 Nm.
Install the wheel shafts.
Raise the engine and transmission using the special tool MKM-883-1.
Note. When mounting the front axle housing, make sure that the support bearing KM-6001-A is properly located in the front engine damping block guide pin and the rear engine damping block bracket. If necessary, adjust the installation position of the engine and gearbox using the special tool MKM-883-1.
Install the front axle housing.
Note. Do not install a center muffler, front exhaust pipe, battery, or battery support.
Install the air filter housing and air intake hose.
Install the left engine damping block.
Attach to the left support of the engine damping block and tighten the 3 mounting bolts to 55 Nm.
Attach the gearbox from above and tighten the 4 mounting bolts to 60 Nm.
Attach the discharge pipeline with a fitting.
Note. The retaining clip should snap into place.
Connect the reversing light switch harness connector.
Disconnect the KM-6001-A special tool from the front axle housing.
Install the center muffler and front exhaust pipe.
Check the fluid level in the gearbox.
Attach the bottom cover of the engine compartment.
Note. Adjust the gear shift rods if necessary.
Install the battery support.
Install the battery.
Program the volatile memory.
Bleed the air from the hydraulic clutch actuator.
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