Gearbox (Removal - Refitting)

REMOVAL

Position the vehicle on a two-post lift.

Disconnect the battery.

Remove:

• the bonnet,
• the battery.

Disconnect the connectors on:

• the injection ECU (petrol version),
• the glow plug control unit (diesel version),
• the fuel filter (diesel version),
• the impact sensor.

Remove the air filter hose.

Remove the battery protection screen bolts (A).

Remove:

• the two mounting bolts (B),

Disconnect the clutch cable.

Remove:

• the upper gearbox and starter motor bolts (unscrew bolt (D) as far as possible),
• the earth strap bolts on the gearbox,
• the two TDC sensor bolts.

• the front wheels,
• the oil catch tray under the gearbox.

On the right side of the vehicle, remove the driveshaft roll pins using tool B. Vi. 31-01.

Remove the right and left sides:

• the brake calipers, and hang them up,
• the mudguards,
• the steering tie-rod ends (T. Av. 476),
• the shock absorber base bolts,
• the cradle-to-side member tie rods (A),
• the driveshaft and hub carrier assembly, releasing it from the lower balljoint.

Check that the left driveshaft rollers do not come out by hand. If they do, check that the needles have not fallen into the gearbox.

Disconnect and remove the starter motor.

Disconnect:

• the reverse light connector,
• the speedometer connector and remove the speed sensor from the transmission.

Remove:

• the exhaust downpipe,
• the complete gear selector rod by removing bolt (E) and the three heat shield bolts to access the base of the gear lever,
• the torque rod bolt,
• the rear gearbox mount.

Remove the engine-to-gearbox tie rod.

To make removal of the steering rack easier, if necessary place a wedge to tilt the engine forward.

Remove the steering rack and secure it.

Fit the engine support and relieve the powertrain.

Positioning on F8Q engine

Positioning on petrol engines

Remove the three bolts securing the support to the gearbox.

Lower the engine as far as possible.

Remove:

• the last upper bolt of the gearbox bellhousing,
• the undershield.

Position the subframe jack (Mot. 1040-01) and lower the vehicle.

Remove the subframe by loosening the four mounting bolts.

Position the transmission jack under the gearbox without lifting it.

Disconnect the gearbox from the engine after removing nut (E) and the engine-to-gearbox stud.

INSTALLATION

Apply MOLYKOTE BR2 grease to the guide tube walls and the fork pads.

Fit the release fork onto the notches of the clutch release bearing.

Mate the gearbox to the engine, avoiding moving the engine upward.

Make sure the engine-to-gearbox locating dowels are present and correctly positioned.

The presence of stud (C) makes mating easier.

Refit:

• the subframe,
• the steering,
• the exhaust downpipe,
• the torque rod.

E7J ENGINE SPECIFIC NOTE

Refit the front exhaust downpipe before the right driveshaft.

Refit the other components in the reverse order of removal.