To perform the work, you will need an inspection pit or overpass, a special device for hanging the power unit or an adjustable stop (hydraulic or screw jack), small container for brake fluid.
Recommendation. The gearbox is heavy and should be operated with an assistant or using an adjustable stop or lifting device of suitable lifting capacity.
We carry out the work in the following order:
1. We prepare the vehicle for maintenance and repair and install it on an inspection pit or overpass.
2. Remove the battery and the platform on which it is installed.
3. Remove the engine sump guard and the front fender liner (the operation is indicated when repairing the windshield washer electric pump).
4. Press the lock and disconnect the wiring harness connector 1 from the reverse light switch. Using an 18 mm open-end wrench, unscrew the bolt securing the wiring harness bracket 2.
5. Having released the retainer, we disconnect the wiring harness block from the vehicle speed sensor.
6. Using a rubber bulb, pump up the brake fluid from the master cylinder reservoir. We drain the brake fluid from the clutch release hydraulic drive into a prepared container.
Recommendation. To prevent the master cylinder reservoir from emptying, you can use a clamp or welding clamp to pinch the clutch release hydraulic hose.
7. Using a slotted screwdriver, pry up and remove the spring retainer of the bleed nipple of the clutch release hydraulic drive.
8. Disconnect the bleed nipple housing and move it away from the gearbox housing together with the clutch release hydraulic hose.
9. Using a plastic cap of a suitable size, seal the working cylinder tube.
Warning! Do not press the clutch pedal with the bleeder nipple removed!
10. Using a mounting blade, remove the ends of the gear shift cables from the ball joints of the levers.
11. Remove the cable from the mounting bracket.
12. Drain the transmission oil from the gearbox and install the oil pan in place.
13. Remove the left and right front wheel drives.
14. Remove the front support of the power unit.
15. Using an 18 mm open-end wrench, unscrew the bolt securing the rear support of the power unit to the bracket. Using a socket wrench of the same size, unscrew the three bolts securing the rear support bracket to the gearbox and remove the bracket.
16. After unscrewing the mounting bolts, remove the front suspension subframe.
17. We hang up the power unit using a special device or install a jack under the left side of the engine, and by slightly raising the engine, we unload the left support of the power unit.
18. Using an 18 mm socket wrench, unscrew the three bolts that secure the upper gearbox to the engine cylinder block.
19. Move the wiring harness bracket to the side. Using the same key, unscrew the fourth bolt of the upper gearbox mount (access to the bolts is hampered by the cooling system components located above them).
20. From the rear of the engine, use an 18 mm open-end wrench to unscrew bolt A, and use a 15 mm wrench to unscrew bolt B, the lower mount of the gearbox to the engine.
21. From the front side of the engine, use a 18 mm wrench to unscrew the front mounting bolt, and use a 15 mm wrench to unscrew the two lower mounting bolts.
22. Remove the left support of the power unit. Using a 16 mm socket wrench, unscrew the three bolts securing the support bracket to the gearbox and remove the bracket.
Note: We will perform further work with an assistant.
Warning! When removing the gearbox, do not rest its input shaft on the driven disk hub and clutch basket petals. This may result in clutch failure.
23. Unscrew the remaining gearbox mounting bolts. Using an adjustable support (jack), lower the left side of the engine. By rocking the gearbox from side to side, we remove it from the guide bushings and carefully remove the primary shaft from the hole in the hub of the driven clutch disc.
24. Move the gearbox until the splines of its primary shaft are completely beyond the clutch basket and remove it.
25. Apply a thin layer of molybdenum grease to the splined surface of the gearbox input shaft and install the gearbox in reverse order. The bolts securing the gearbox to the engine block with a 15 mm wrench are tightened to a torque of 45 Nm, the bolts with a 18 mm wrench are tightened to a torque of 75 Nm. The bolts securing the left support bracket of the power unit are tightened to a torque of 62 Nm. The bolts securing the rear support of the power unit are tightened to a torque of 100 Nm.
26. After installing the box, check the operation of the gear shift drive and, if necessary, adjust the length of the drive cables.