Removing and refitting the gearbox

REMOVAL

• Disconnect the battery.
• Remove the driveshaft bolts.
• Remove the subframe (see relevant operation in chapter 'SUSPENSION-AXLES-GEOMETRY').
• Remove the catalytic converter clamp (1) and its rubber mount (Fig.2).
• Remove the gear shift and selector cables.
• Disconnect the reverse light switch.
• Lower the engine on the left side until the bolts (2) of the engine mount (3) are accessible (Fig.3).
• Remove the bolts (4), then the link rods (5) (Fig.2).
• Remove the bolts (2), then the engine mount (3) (Fig.3).
• Remove the driveshafts (see relevant operation in chapter 'TRANSMISSIONS').
• Position a hydraulic support jack with a suitable block of wood under the engine oil sump.
• Remove the gearbox mount.
• Disconnect the hose (6) from the breather (7), then remove the clip (8) (Fig.2).

Fig. 2

Fig. 3

• Remove the starter motor (9) (arrows).
• Support the gearbox.
• Remove the gearbox-to-engine mounting bolts (10).
• Separate the gearbox from the engine and lower it out of the vehicle, taking care with the various harnesses and lines.

INSTALLATION

To refit, reverse the removal procedure, observing the following points:

• check that the clutch disc is correctly centred,
• always replace all self-locking nuts or bolts,
• lightly grease the input shaft splines all around with high-temperature grease,
• observe the specified tightening torques,
• check that the gearbox locating sleeves are in place on the engine,
• check the gearbox oil level,
• fill and bleed the clutch control,
• check for leaks with the engine running,
• if necessary, adjust the gear shift control.

Gearbox housings

1. 1
   Clutch housing
2. 2
   Gear train housing
3. 3
   Locating sleeve
4. 4
   Seal
5. 5
   Bolt (replace): 2.3 dan.M
6. 6
   Bearings
7. 7
   Oil shields
8. 8
   Bolt: 2 dan.M
9. 9
   Drain plug (replace): 3.5 dan.M
10. 10
    Filler plug (replace): 3.5 dan.M.

Gear train

1. 1
   Cylindrical bearing
2. 2
   Input shaft
3. 3
   6th idler gear
4. 4
   3rd idler gear
5. 5
   4th/5th idler gear
6. 6
   Circlips
7. 7
   Output shaft 1st to 4th
8. 8
   Needle bearings
9. 9
   Driven gears
10. 10
    Sliding sleeves
11. 11
    Synchroniser hubs
12. 12
    Synchroniser locking mechanisms
13. 13
    Synchronisers
14. 14
    Synchroniser ring
15. 15
    Washers
16. 16
    Output shaft 5th and 6th
17. 17
    Reverse intermediate shaft.