Contents: Removal ⇊ Installation ⇊
Removal
1. Disconnect both cables from the battery (negative first). Remove the battery and its support tray (see Chapter Engine electrical equipment).
Warning! If the car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!
2. Remove the air intake sleeve and air cleaner housing (see Chapter Power and exhaust systems).
3. Disconnect the starter wiring and remove the starter (see Chapter Engine electrical equipment).
4. Disconnect the transmission ground bus and the reverse light switch sensor wiring (see Section Checking and replacing the reverse light switch sensor). Disconnect the wiring harness clamp from the transmission housing.
5. Engage reverse gear.
6. Disconnect the gear selection and shift drive cables from the box (see Section Removal and installation the drive and gear shift lever).
Note: There is no need to release the cables from the support brackets.
7. Disconnect the wiring from the speed sensor (VSS).
8. Remove the union nut connecting the clutch hydraulic hose to the hydraulic pressure line. Remove the pressure line and the clutch slave cylinder with the push rod (see Chapter Clutch and drive shafts).
Caution! Try not to bend or twist the pressure line (after disconnecting, tie it up with wire immediately). Do not press the clutch pedal with the slave cylinder removed.
9. Unscrew the bolts securing the front powertrain support bracket to the engine block, remove the rear support mounting bracket (see Chapter Engine).
10. Release the wiring harness from the clips and remove the two upper gearbox mounting bolts.
11. Loosen the front wheel nuts, jack up the car and place it on supports. Hang the power unit from above using a winch or a beam placed over the edges of the hood.
12. Remove the front wheels.
13. Remove the crankcase guard.
14. Drain the transmission oil (see Chapter Settings and ongoing maintenance).
15. Disconnect the lower suspension arms from the steering knuckle assemblies, then release the damper forks from the lower arms (see Chapter Suspension and steering).
16. Release the left drive shaft from the intermediate shaft and the right drive shaft from the transmission (see Chapter Clutch and drive shafts). Tie the drive shafts to the suspension components with wire, trying not to let them hang on the outer CV joints. To prevent dirt from getting in, wrap the joint assemblies in plastic bags.
17. Unbolt the bearing support and release the intermediate shaft from the left side of the gearbox (see Chapter Clutch and drive shafts).
18. Unscrew the right damper fork clamp bolt and separate the latter from its shock absorber (see Chapter Suspension and steering).
19. Remove the mounting bolts from both push rods (see Chapter Suspension and steering).
20. Release the power steering hydraulic line from the holders on the subframe.
21. Remove the subframe assembly, having first marked the position of the latter relative to the chassis.
22. Remove the clutch access cover or power booster assembly.
23. Remove the intake manifold mounting bracket.
24. Rotate the inner CV joint of the right drive shaft so that it does not interfere with the removal of the gearbox.
25. Support the transmission with a jack (if possible, a special one), securing it to the head of the latter with a safety chain.
Note: Special transmission attachments are available for the floor jack head. Raise the gearbox, completely relieving its supports.
26. Remove the transmission support with its bracket (see Chapter Engine). Unscrew the threaded stud from the gearbox housing.
27. Remove the transmission mounting bolts above the intermediate shaft and near the location of the clutch actuator cylinder. Remove the two powertrain support bracket bolts.
28. Finally, make sure that all reinforcement lines and wiring harnesses are disconnected, then, moving the jack, carefully separate the transmission from the engine. Having completely released the primary shaft of the manual transmission from the clutch assembly, remove the box from under the car.
29. After removing the gearbox, access to the clutch components is opened, the condition of which, taking advantage of the opportunity, should be checked immediately. Usually, when removing the manual transmission, it is customary to replace the clutch (see Chapter Clutch and drive shafts).
Installation
1. If removed, reinstall the clutch components (see Chapter Clutch and drive shafts).
2. Secure the transmission to the jack as you did during dismantling and carefully slide it under the car, lifting it to its normal position behind the engine. Carefully engage the input shaft with the splines of the clutch disc hub, making sure the guide pins fit into the mating holes in the engine mating surface. Do not use force under any circumstances - if the input shaft does not fit into the clutch disc hub, adjust the angle of the gearbox and turn the shaft slightly to achieve correct spline alignment.
3. Screw in the lower bolts securing the manual transmission to the engine, as well as the bolts of the rear support bracket. Tighten the fasteners to the required torque.
4. Screw in the threaded stud and install the transmission mount with the bracket. Tighten the mount mounting bolts to the body, do not tighten too tightly, screw in the through bolt, then tighten the three nuts that secure the bracket to the transmission case. Finally, tighten the mount through bolt to the required torque (see Specifications in Chapter Engine).
5. Install the subframe in place, making sure that the mounting marks applied during dismantling are correctly aligned. Tighten the fasteners to the required torque. Secure the hydraulic line of the power steering to the clamps on the subframe.
6. Install the power booster assembly and intake manifold mounting bracket.
7. Reinstall the intermediate and drive shafts. Do not forget to replace the stopper retaining clips (see Chapter Clutch and drive shafts).
8. Connect the suspension push rods to the lower arms, install the damper forks, then connect the lower arms to the steering knuckles (see Chapter Suspension and steering).
9. Reinstall the engine guard and front wheels, then lower the vehicle to the ground.
10. Further installation is carried out in the reverse order of dismantling of the corresponding components.
11. Fill the gearbox with the required amount of transmission oil of the required grade (see Chapter Settings and ongoing maintenance).
12. Bleed the clutch hydraulic system (see Chapter Clutch and drive shafts) and make sure that the latter assembly is functioning properly.
13. Perform road tests of the vehicle, checking the correct operation of the manual transmission. Inspect the power unit for signs of fluid leaks.
14. If vibrations occur, loosen and retighten the fasteners of the power unit mounts (see Chapter Engine).
15. Adjust the front wheel alignment angles.