1. Gearbox assembly.
Note.: observe the installation direction and tightening torques of the bolts.
Caution. When removing the gearbox assembly from the vehicle, always replace the concentric clutch slave cylinder with a new one. To remove the gearbox assembly, return the concentric clutch slave cylinder insert to its original position. Dust from the working surfaces of the clutch discs can damage the clutch slave cylinder seal, which will lead to leaks of the clutch hydraulic fluid.
Removal
1. Disconnect the negative terminal of the battery.
2. Remove the breather hose.
3. Remove the air filter housing with the air intake duct.
4. Remove the battery.
5. Disconnect the connectors (A) and remove the bracket (1).
6. Drain the working fluid of the clutch hydraulic drive, then disconnect the pipeline from the concentric clutch release cylinder.
Caution: Do not press the clutch pedal while removing the gearbox.
7. Disconnect the position sensor connector.
8. Disconnect the ground cable.
9. Remove the wiring harness from the gearbox assembly.
10. Disconnect the selector and shift cables from the transmission assembly.
11. Remove the starter.
12. Remove the engine protective pan.
13. Drain the tsoosmissiossi8 oil.
14. Remove the front exhaust pipe.
15. Remove the front drive shafts.
Note: Insert a suitable plug into the differential side seal after removing the front drive shaft.
16. Remove the rear engine mounting brackets and rear torque rod.
17. Remove the front suspension arms and struts.
18. Place a suitable jack under the gearbox assembly and a second jack under the engine assembly.
Caution: When installing a suitable jack, make sure that it does not touch the switches and sensors.
19. Loosen the gearbox mounting bolts.
20. Loosen the tie rods of the engine and gearbox.
21. Remove the front gearbox assembly from the axle.
Attention.
- When removing, secure the gearbox assembly on a suitable jack.
- The gearbox assembly must not cling to the wiring harnesses and hydraulic clutch lines.
22. Remove the concentric clutch release cylinder.
Caution. When the gearbox assembly is removed from the vehicle, the concentric clutch slave cylinder must always be replaced with a new one. To remove the gearbox assembly, the concentric clutch slave cylinder insert must be returned to its original position. Dust from the working surfaces of the clutch discs can damage the clutch slave cylinder seal, which will lead to leaks of the clutch hydraulic fluid.
Installation
Installation is carried out in the reverse order of removal.
Note: Tighten the gearbox-to-engine mounting bolts, observing the installation direction and tightening torques. The figure shows the view from the engine side.
A: from gearbox to engine
B: from engine to gearbox
Post-installation check
Attention.
- The gearbox assembly must not be caught on the wiring harnesses and hydraulic clutch lines.
- When installing the gearbox assembly, do not allow the input shaft to come into contact with the clutch cover.
Check the control rods for leaks.
Check the oil level and check for leaks from the gearbox.
Bleed the clutch hydraulic system.