Removing
Note. Removal and installation of gearbox shafts, as well as disassembly and assembly of the differential can be carried out without removing the gearbox. Before removing the shafts, it is necessary to extend the input shaft of the gearbox to failure, as described in section «Clutch», and remove the gearbox rear cover.
Disconnect the clutch cable from the clutch release lever.
Loosen the bolt securing the shift rod clamp.
Disconnect the flexible speedometer drive shaft from the gearbox.
Disconnect the wire from the reverse light switch (if it is installed).
Remove the three lower bolts securing the clutch housing to the engine block.
Disconnect wire «masses» from the side member, hang out the car and remove the front wheels.
Unscrew the nuts of the pins of the ball joints of the front suspension arms and press the ball joints of the arms from the steering knuckles, made integral with the front suspension strut.
Press the front drive shafts out of the differential outlets.
Remove the front wheel drive shafts from the side gears of the differential and immediately close the holes in the differential with plugs.
Unscrew the plug from the gearbox rear cover. Mark the position of the gearbox input shaft in relation to its gear assembly.
Remove the circlip and remove the barrel bolt from the rear end of the transmission input shaft.
Using the Kukko 22-1 puller and the KM 449-1 tool, move the input shaft to the stop so that the splines of the input shaft are removed from the splines of the hub of the clutch disc.
Sling the engine and remove the left bracket of the front suspension of the power unit.
Remove the rear suspension bracket of the power unit.
Remove the exhaust pipe mounting bracket from the gearbox.
Install a hydraulic jack under the gearbox, unscrew the upper bolts securing the clutch housing to the block and remove the gearbox.
Installation
Install the gearbox on the engine block and tighten the mounting bolts.
Install the rear suspension bracket first, then the front suspension bracket of the power unit. Apply locking compound to the threads of the bracket fastening bolts and tighten the bolts to the required torque.
Lubricate the bearings of the differential box with gear oil, install new circlips on the wheel drive shafts and insert the shafts into the side gears with a screwdriver until the circlips snap into place.
By hand, move the input shaft until its splines enter the splines of the hub of the clutch disc. Using tool KM 564, tighten the cylindrical bolt to fit the input shaft. Install a new retaining ring, lubricate the thread of the plug with sealant and screw it into the gearbox rear cover. The protrusion of the plug above the plane of the crankcase should not be more than 4 mm.
Attach the ball joints of the front suspension arms to the steering knuckles, tighten the new nuts of the ball studs and lock them with new pins.
Install wheels, connect wire to reverse light switch, connect clutch cable and wire «masses».
Attach the flexible speedometer drive shaft to the gearbox.
Adjust the shift actuator as follows.
Check the oil level in the gearbox housing and top up if necessary.
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