Contents: Removal ⬇ Installation ⬇
Removal
1. Disconnect the cable from the clutch release lever.
2. Disconnect the wiring from the reverse light switch (see photo).
Photo 7.2. Reverse light switch wires.
3. Loosen the clamping bolt and disconnect the gear engagement rod.
4. Disconnect the speedometer drive cable from the gearbox housing by unscrewing the knurled ring or bolts securing the locking plate (depending on the model).
5. Raise and support the front of the car.
6. Remove the left front wheel.
7. Disconnect the ground bus connecting the gearbox to the machine body (see photo).
Photo 7.7. Gearbox grounding bus.
8. Remove the bracket of the long exhaust pipe from the gearbox housing (depending on the model).
9. Disconnect the anti-roll bar from the left lower suspension arm.
10. Remove the bolts securing the suspension arm support (see chapter 10). With the suspension arm and its support suspended on the steering knuckle only by the ball joint, turn the arm to the side so that it does not interfere.
11. Using a suitable tool, disconnect the left drive shaft from the gearbox (see chapter 7) (be prepared for some oil to spill out of the box when doing this). Pull the shaft towards you and remove it from the box.
12. Unscrew the plug from the end cover of the gearbox.
13. Remove the opened retaining ring (see photo).
Photo 7.13. Retaining ring of the gearbox input shaft.
Figure 6.13. Speedometer cable and connection point of the gearshift rod to the gearbox
14. Now you will see a screw with a 12-sided hole in the head, which requires a special key to remove (in principle, you can try to get by with a hex key) (see photo).
Photo 7.14. Removing a screw with a 12-sided hole in the head from the drive shaft.
Figure 6.14. Bolts securing the suspension arm support (shown by arrows) — models with 1.3 l engine and some models with 1.6 l engine (see chapter 10): A. Center bolt on position sleeve.
15. Unscrew and remove the screw.
Figure 6.15. Scheme of fastening the tip of the anti-roll bar: A = 38.0 mm.
16. As stated in chapter 5, the manufacturer recommends using a special tool to remove the gearbox input shaft from the clutch driven disc. To do this without a special tool, you can unscrew one of the 4 bolts that secure the gearshift cover to the top of the gearbox housing and screw this bolt into the end of the drive shaft. Using pliers, grasp the screw and pull the drive shaft out of the clutch driven disc (don't forget to put the bolt back on the gearshift cover afterwards).
17. Support the engine with a jack or hang it on a lift. Support the gearbox with a garage jack.
18. Disconnect the left rear support bracket from the gearbox and from the rubber mount (see photo).
Photo 7.18. Rear left gearbox support bracket.
19. Disconnect the left front support bracket from the gearbox and from the rubber mount.
20. Move cables, wires and disconnected parts away from the box.
21. Remove the bolts securing the clutch housing to the engine.
22. Loosen the bolts and remove the lower cover of the flywheel housing (looks towards the drive end of the engine).
23. Lower the box. The right drive shaft will fall out, so support it in advance. Pull the box out from under the car.
24. Clean the gearbox from dirt. If the box is to be disassembled, it should be moved to the work table.
Installation
25. Move the box under the car and lift it with a jack in order to connect it to the engine. If you have disassembled the clutch, you should center the driven disc (see chapter 5). While lifting the box, insert the right drive shaft into it.
26. Insert the flywheel flange mounting bolts and tighten them to the specified torque. Replace the flywheel housing cover.
27. Install the front and then rear engine mounts.
28. Connect the drive shafts to the box and secure their retaining rings by placing a heavy punch against the weld bead of the hinge joint and striking the punch sharply with a hammer (see chapter 7).
29. Install the suspension arm with support (see chapter 10).
30. Clean the threads of the lever support bolts from the old thread locking compound and apply new compound. Insert the bolts and tighten them to the required torque (see chapter 10).
31. Connect the anti-roll bar to the suspension arm. Be careful not to overtighten the mounting bolt or nut. They must be tightened just enough to maintain the dimension (A) shown in the figure 6.15.
32. Insert the transmission drive shaft into the splines of the clutch driven disk hub. Screw in a 12-sided socket head cap screw and install the retaining ring.
33. Install the screw plug on the end cover of the box. It is very important that the plug does not leak, so on 4-piece boxes you should apply thread sealant to the plug threads or wrap it with thread sealing tape. On 5-speed gearboxes, the plug has a different design and can be installed without prior preparation (see photos).
Photo 7.33A. Wrap the plug threads with thread sealing tape.
Photo 7.33B. The gearbox end cover plug installed in place.
34. Connect the grounding bus.
35. Install the wheel in place.
36. Connect the wiring to the reverse light switch. Connect the clutch and speedometer cables.
37. Connect and adjust the gear shift rod (see sections 5 and 6).
38. Lower the car to the ground.
39. Pour oil into the box.
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