Transmission, Installing
Transmission, installing
Special tools:
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
Cleaning and lubricating the input shaft
The input shaft must be lubricated before a manual transmission is installed.
Checking before installing
Check that the gearbox and engine mating surfaces are absolutelyclean.
Also check that the guide sleeves towards the engine are in position and are free of faults.
Lubricate the holes in the gearbox (for the guide pins). Use a little grease.
Adjusting the position of the gearbox and engine
Adjust the height and angle with the mobile jack and the gearbox fixture.
Locate the gearbox on the engine.
Ensure that the gearbox goes straight in, in relation to the engine, and that no deviation occurs in the clutch driven plate centre.
Install and tighten the screws for the gearbox
Install all 7 screws for the gearbox and engine.
At the same time, check that the whole of the gearbox is in contact with the engine.
First tighten alternately and crosswise to light contact.
Then tighten the gearbox / engine screws crosswise. Tighten to 50 Nm.
Remove the fixture from the gearbox.
Install the sub-frame and gearbox components
Install:
- the mounting for the cable bracket. The screws for the mounting. Tighten the screws. Tighten to 25 Nm
- the bump stop on the sub-frame. Install the rubber plug on the gearbox
- the bracket for the connectors
- the screw and nut for the cable harness clamp
- the bracket for the cable. Install the screws. Tighten to 25 Nm.
Lower the car
Lift up the engine and gearbox to the horizontal position
Note! Right-hand drive cars: Before lifting the engine, check that the lower steering column has not slipped over the upper steering column at the pedal box.
Raise the car
Install the rear engine mounting
Install:
- the rear engine mounting on the gearbox
- the 4 screws for the engine mounting. Tighten to 50 Nm.
Install the screw for the rear engine pad
Lift the anti-roll bar mounting a few mm. Use a jimmy bar. This makes it easier to insert the tool and the screw.
Tighten to 50 Nm.
Install the collision protection system over the steering gear (right-hand drive cars only)
Tighten the screw and nut. Tighten to 80 Nm.
Install the sub-frame on the bodywork
Note! Use 4 new M14 screws. Lubricate the screw threads.
Note! When the sub-frame is raised, ensure that the screws for the steering gear locate in the frame. RHD cars: Also align the collision protection system which is positioned between the steering gear and frame.
Begin the installation of the sub-frame on the right-hand side.
Use the mobile jack to lift the frame toward the bodywork until the frame is approximately 10 cm from the bodywork.
Install the left drive shaft on the gearbox, the stub axle and the control arm
Note! Take care not to damage the drive shaft seal in the transmission.
Press in the drive shaft so that the snap ring locates in the groove. Pulling the constant velocity joint to check that the drive shaft is secure.
Locate the drive shaft in the wheel hub. Install the screw loosely in the drive shaft.
Install the stub axle on the control arm.
Install the lock nut loosely.
Raise the frame to the bodywork. Install new screws in the frame.
Move the mobile jack to the right-hand side
Install the right drive shaft in the gearbox, the stub axle and the control arm
Note! Take care not to damage the drive shaft seal in the transmission.
Install the drive shaft pilot bearing cover
Tighten with 25 Nm.
Locate the drive shaft in the wheel hub. Install the screw loosely in the drive shaft.
Lift the sub-frame
Install:
- the mobile jack under the sub-frame. Remove both the sub-frame screws. Lower the sub-frame approximately 10 cm
- the stub axle on the control arm
- the lock nut loosely.
Lift the sub-frame to the bodywork. Install new screws in the frame.
Press the evaporator cable and the oil pipe into place in the sub-frame clips.
Tighten the screws for the sub-frame on both sides
Install the screws for the support bracket.
First tighten the screws on the left-hand side of the subframe, followed by the right-hand side, to 105 Nm + 120°. Use a bevel protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.
Then tighten the screws on the subframe brackets. Tighten to 50 Nm.
Cars with parking heaters:
Install the parking heater in the bracket. Tighten the nuts. Tighten to 25 Nm.
Install and tighten the suspension components (both sides)
Install the nut for the track rod. Use a new nut. Tighten to 70 Nm.
Tighten the drive shaft screw. Use a new screw. Counterhold using a crow bar in the brake disc.
Install:
- the screw for the brake pipe bracket on the body. Tighten to 10 Nm
- the lock nut for the anti-roll bar link at the spring strut. Use a new lock nut. Tighten to 50 Nm.
Note! Counterhold the ball joint pinion when tightening the lock nut. This is so the ball joint boot does not turn.
Tighten the ball joint pinion
Note! Counterhold the ball joint pinion while tightening so that the ball joint boot cannot turn. Tighten to 80 Nm.
Raise the car
Install the screw for the front engine pad and the torque rod mounting in the sub-frame
Install:
- the screw for the front engine pad. Tighten to 50 Nm
- the torque rod mounting on the gearbox. Tighten to 50 Nm.
Install the screws for the bracket for the heated oxygen sensor (HO2S) cable
Install:
- the screws for the bracket
- the connectors in the sub-frame. Connect the connectors.
Reinstall the front cross member
Install:
- the rubber mounting for the exhaust pipe on the cross member. Tighten to 10 Nm
- the brake pipe in its holders
- the cross member on the bodywork. Tighten the screws. Tighten to 25 Nm.
Install the centre and rear cross members. Tighten to 25 Nm.
Install the splash guards, cable conduit and wing liner
Install
- the splash guard under the engine
- the cable conduit on the right-hand side of the sub-frame
- the screw for the ground lead bracket in the sub-frame. Tighten to 10 Nm
- the front splash guard
- the nuts for the left hand wing liner
- the wheels. See Installing wheels Service and Repair.
Lower the car
Install the remaining screws on the gearbox and the engine
Tighten to 50 Nm.
Install the ignition setting sender. Install the screw
Tighten to 10 Nm.
Install the ground lead and the clamp for the cable harness
Install:
- the ground lead on the gearbox
- the screw and clamp for the cable harness in the bracket. Tighten to 10 Nm.
Install the screw on the clamp for the oil pipe. Tighten.
Install the clutch hose on the clutch cylinder pipe junction
Use a new seal.
Remove the hose clip.
Bleed the clutch
Install the gear selector control on the gearbox
Apply a thin layer of silicon sealant on the gearbox.
Install:
- the gear selector control in the gearbox
- the screws. Tighten to 25 Nm.
Install the gearbox cables on the gearbox and the levers
Note! The yellow marked cable must be outermost toward the side member.
Install:
- the reverse lamp switch
- the mechanical cables in their mountings. Secure with the clips
- the mechanical cables on the levers. Lock with the locking.
Install the air cleaner (ACL) housing. Install the cross member
Install:
- the air cleaner (ACL) housing. See Brake pipe master cylinder / ABS unit, replacing Brake Pipe Master Cylinder / ABS Unit, Replacing
- the cross member. See Brake fluid reservoir, replacing, L.H.D Brake Fluid Reservoir, Replacing, L.H.D
- the integrated relay / fusebox. See Brake pipe master cylinder / ABS unit, replacing Brake Pipe Master Cylinder / ABS Unit, Replacing.
Check the rubber grommet for the steering shaft at the lower bulkhead
Check that the rubber boot is positioned correctly in the bodywork. Adjust if necessary.
Check that the gear positions are working.
Check the oil level in the gearbox. Top up the oil if necessary
Tighten the plug to 35 Nm.