Removal and installation

PROCEDURE

Clutch housing shield 1 – shield; 2 – gearbox; 3 – engine block

Removal PROCEDURE 1. Position the vehicle over the inspection pit. 2. Disconnect the cable from the negative battery terminal. 3. Drain the oil from the gearbox. 4. Disconnect the ground wire from the gearbox bracket. 5. Disconnect the speedometer flexible shaft. 6. Disconnect the clutch cable. 7. Disconnect the wires from the reverse light switch. 8. Remove the starter motor (see subsection 12.3.1). 9. Attach the engine to the lifting eyes using a crane or hoist, since after the gearbox is disconnected the engine will rest only on the front mounts. If no crane or hoist is available, place a beam on the body flanges with rags underneath to avoid damaging the body, and secure the engine lifting eyes to the beam with thick steel wire. 10. Disconnect the gear shift rods. 11. Remove the front gearbox mount bracket. 12. Unscrew the upper bolts securing the clutch housing to the engine. 13. Unscrew the bolt securing the heater pipe to the engine block (gearbox type 020 only). 14. Disconnect the axle shafts from the axle shaft flanges (see subsection 7.2). 15. Remove shield 1 (see fig. Clutch Housing Shield) from the clutch housing. 16. Unscrew the two bolts and remove the shield located behind the right axle shaft flange (gearbox type 020: one bolt). 17. Disconnect the exhaust pipe from the exhaust manifold (gearbox type 020 only). 18. Unscrew the remaining bolts securing the clutch housing to the engine. 19. Remove the rear gearbox mount bracket. 20. Disconnect the engine mount bracket (gearbox type 020 only); the engine will rotate, which allows the gearbox to be removed. 21. Move the gearbox away from the engine so that the clutch housing slides off the studs and the input shaft disengages from the clutch driven disc. Lower the engine if necessary. 22. Remove the gearbox from under the vehicle. Installation PROCEDURE 1. Install the gearbox in the reverse order of removal, observing the following. 2. Lightly grease the input shaft splines with graphite grease or Moly paste. 3. Tighten the clutch housing-to-engine bolts to 45 N·m for M10 and 75 N·m for M12. 4. Install the gearbox with the engine so that the mounts sit without misalignment, then tighten the mount bolts. Tightening torques: front bracket-to-mount bolt 60 N·m, and to the gearbox 35 N·m; rear bracket-to-mount and gearbox bolts 60 N·m; engine mount bracket-to-engine block bolts 25 N·m. 5. Adjust the clutch drive and the gear shift linkage.