The main malfunctions, for the elimination of which it is necessary to remove the manual transmission from the car:
- elevated (compared to usual) noise;
- difficult gear shifting;
- spontaneous disengagement or fuzzy engagement of gears;
- oil leakage through seals and gaskets.
In addition, the gearbox is removed to replace the clutch, flywheel and rear engine crankshaft oil seal.
USEFUL TIPS: The work of removing and installing the gearbox is very laborious, so be sure to first make sure that its malfunctions are not caused by other reasons (insufficient oil level, defects in the clutch release drive, loosening of the gearbox, etc.).
The gearbox is quite heavy and its shape is not comfortable to hold, so we recommend removing the gearbox with an assistant.
1. Remove the battery (see «Removing and installing the battery»).
2. Remove the battery mounting shelf (see «Removal and installation of the shelf of fastening of the rechargeable battery»).
3. Remove mudguards and crankcase protection (see «Removal and installation of mudguards and engine crankcase protection»).
4. Remove the front wheel drives (see «Removal and installation of front wheel drives»).
5. Remove the starter (see «Removal and installation of a starter»).
6. Disconnect the wiring harness connector from the reverse gear switch.
7. Remove the retainer and disconnect the hose tip from the clutch release intermediate tube adapter.
8. Remove the hydraulic clutch release pipeline from the holder on the body bracket and move it aside.
9. Disconnect the harness holders from the transmission brackets and move the harness to the side.
10. Pry off the tip of the shift cable with a screwdriver...
11.... and disconnect the tip of the cable from the gear lever, overcoming the elastic resistance of its spring retainer.
12. Pry off the tip of the gear selection cable with a screwdriver...
13.... and disconnect it from the gear lever, overcoming the elastic resistance of the spring retainer.
14. Move back the retainer of the sheath of the gear selection cable...
15.... and remove the stop from the bracket on the gearbox.
16. Similarly disconnect from an arm an emphasis of a cable of a choice of transfers.
17. Attach the lifting gear straps to the rear transport eyes of the power package and tension the straps.
18. Remove the left powertrain mount (see «Replacement of the left support of a suspension bracket of the power unit»).
19. Remove the front suspension cross member (see «Removal and installation of a cross-beam of a forward suspension bracket»).
20. Remove the front pipe of the exhaust system (see «Downpipe replacement»).
21. Install supports under the gearbox and engine housings.
22. Turn out on two top bolts of fastening of a transmission to the block of cylinders of the engine on the right...
23....and to the left.
24. Turn out three bolts of fastening of an arm of a forward support of a suspension bracket of the power unit to a transmission and remove an arm.
25. Remove the three bolts securing the clutch housing to the engine oil sump.
26. Move the gearbox as far back as possible (the input shaft must disengage from the hub of the clutch disc), remove the support from under it and remove the gearbox from the vehicle.
WARNING: When removing the gearbox, do not rest the end of the input shaft on the petals of the diaphragm spring, so as not to deform them.
27. Establish a transmission and all removed details and knots in an order, the return to removal.
USEFUL ADVICE: Before installing the gearbox, we recommend lubricating the splines of the input shaft with a thin layer of refractory grease. Check with a special mandrel how the clutch disc is centered (see «Removal and installation of clutch»). Before attaching the front wheel drives to the gearbox, replace the retaining rings on the splined shank of the inner joints with new ones. Otherwise, there is a possibility of disconnection of the drives from the gearbox while driving.
28. Fill the gearbox with oil (see «Checking the level, topping up and changing the oil in a manual transmission»).
29. If necessary, adjust the gearbox control drive (see «Adjustment of a drive of management of a manual transmission»).
30. Fill the working fluid into the reservoir of the main brake cylinder (into its section designed to power the hydraulic clutch release) and bleed the air from the hydraulic clutch release (see «Bleeding the hydraulic clutch release»).