Before disassembling, all wires and hoses must be marked. This will greatly facilitate the assembly process.
1. Disconnect the ground cable from the battery and the transmission housing. Unlock the steering column. Set the lever to neutral.
2. Disconnect the following cables and wires:
- a. Clutch cable on the release lever.
- b. Reverse light switch wires.
- c. TCS (Transmission Controlled Spark) switch wires.
- g. Starter solenoid wire.
3. Release the engine wiring harness from the clamp on the clutch housing. Remove the two upper transmission mounting bolts.
4. Raise and securely support the front of the vehicle with struts. Make sure the struts are securely positioned. Drain the oil from the gearbox.
5. Remove the front wheels. Place a suitable jack under the gearbox.
6. Disconnect the speedometer cable.
When disconnecting the speedometer cable, it is not necessary to remove the entire cable mounting assembly. Remove the end housing, then the cable retaining clip. and pull the cable out. Do not disassemble the cable mounting assembly unless absolutely necessary.
7. Disconnect the shift lever pivot rod from the clutch housing. Remove the bolt from the shift rod bracket.
8. Disconnect the ball joints of the connecting rod and remove them with a ball joint puller.
9. Remove the lower control arm ball joint bolt on the right side of the lower control arm. Use a puller to pull the ball joint out of the knuckle. Remove the shock absorber fork bolt.
10. Disconnect the drive shafts (half-axles) from the gearbox. Move the axles out of the way, but do not leave them hanging, but secure them with wire or twine. Remove the right torque rod.
11. Remove the shock absorber bracket from the gearbox. Unscrew the clutch housing mounting bolts from the front gearbox support.
12. Unscrew the clutch housing mounting bolts from the rear gearbox bracket. Remove the clutch housing.
13. Remove the starter mounting bolts and pull the starter assembly out through the chassis. Remove the transmission mounting bolts.
14. Pull the transmission out of the engine block until it is off the two 14mm mounting pins and lower it with a jack.
WARNING: Do not leave the gearbox hanging on the input shaft. Remove the gearbox completely and in one go.
To install:
15. Support the gearbox with a jack. Clean and lubricate the sliding surface of the release bearing.
16. Check that the two dowel pins are in place in the clutch housing.
17. Raise the assembly until the pins are flush with the input sockets in the cylinder block.
18. Move the gearbox toward the engine and insert the input shaft into the grooves of the clutch disc. If the left suspension has not been disassembled and is in place, install new spring clips on both axles and carefully insert the left axle into the differential at the same time as installing the gearbox.
19. Move the transmission assembly until it is flush with the edge of the engine block.
20. Tighten the bolts until the clutch housing is positioned against the engine block.
21. Fit the front gearbox mount bolts and then tighten them in turn to a torque of 45 Nm.
22. Install the rear gearbox support, tightening the bolts to 45 Nm.
23. Install the upper steering rod together with its brackets. Tighten the bracket mounting bolts to 65 Nm and the tie bolts to 75 Nm.
24. Carefully remove the jack from under the gearbox.
25. Install the starter.
26. Install the drive shafts if not already installed.
27. Install the ball joints of the lower arm and connecting rod. Tighten the shock absorber fork bolts.
28. Connect the gear shift rod.
29. Connect the gear shift lever.
30. Connect the gearshift lever pivot rod to the clutch housing. Tighten the 8 mm bolts to 22 Nm.
31. Install the front wheels.
32. Carefully check that the Gearbox drain plug is in place and tightly tightened.
33. Lower the car to the ground.
34. Connect the clutch cable to the release lever.
35. Lubricate the new sealing ring with clean oil and install it into the speedometer socket. Install the socket into the gearbox and secure with the keyed bolt.
36. Secure the engine wiring harness to the clamp on the clutch housing.
37. Connect the electrical wiring from the engine compartment to the starter, starter solenoid and reversing light switch.
38. Fill the gearbox with the required amount of oil.