Instruction. Before installing the gearbox, push the clutch release lever towards the gearbox housing and secure with a mounting bolt or M8x35 bolt. Unscrew after installing gearbox. Then close the hole with the 3rd fixing bolt of the drive cable counter support.
When replacing the gearbox, the speedometer sender -G22- must be reinstalled (pic.), gearshift lever, intermediate gear selection lever, as well as a bracket for connecting tubular-hose line. Clean input shaft splines and apply a thin coat of spline grease for clutch disc -G 000 100-. The clutch disc should move easily back and forth on the input shaft. Check the presence of fitted bushings in the cylinder block for centering the engine/gearbox, insert bushings if necessary. When replacing the gearbox, pay attention to the correct installation of the metal spacer. Align adjusting jig -3282/8- and gearbox parallel to each other and attach retaining support to gearbox.
Install the gearbox lift under the vehicle. Arrow -B- on setting gauge -3282/8- points in direction of travel. Move the gearbox with the spindles of the left gearbox gripper -3282- to an inclined position. Install CP. Screw in the screws for the bottom mounting of the engine/gearbox.
Secure gearbox bracket -A- with new bolts -arrows-. Screw in the upper engine/gearbox mounting bolts. Raise the power unit on the lead screws of the traverse -10. 222 A-. Move engine/gearbox to installation position.
Fit new hexagon bolts -arrows B- of left power unit support into gearbox support.
Attention! Only remove bracket -10.222 A- after tightening screws on left gearbox bracket to torque.
Install pendulum support -arrows-. Use new screws for fastening.
Connect electrical connector to speedometer sender -G22- (-arrow-).
Fit small shield -A-, if fitted, behind right drive shaft flange -arrow-. Attach the strut to the stabilizer and the arm to the steering knuckle. Attach drive shafts to gearbox. If available, install the protective cap of the right inner CV joint on the engine. Install starter.
Remove ground wire -B- from lower starter mounting bolt. Plug in connector for reversing light switch -F4- (-2-) and connector -3- for the starter. Unscrew cable -4- from solenoid switch terminal 30.
Install the working cylinder, fix the tubular-hose line on the gearbox bracket.
Screw cable counterhold onto gearbox -arrows-.
Fit selector lever and secure with new nut -arrow 2-. Push in intermediate selector lever and secure with clip -arrow 1-. Adjust gearshift mechanism.
Install cross support -A-. Install the engine cover. Connect battery. After connecting the battery, check and activate all vehicle systems (radio, clock, electrics of the Comfort system). Check the transmission oil level in the manual gearbox.
Install the power unit soundproofing cover, if equipped.
Tightening torques
Gearbox to engine
Pos. | Screw | PC. | Nm |
1 1) | М12х55 | 1 | 80 |
2 | М12х55 | 2 | 80 |
3 | M10x50 | 2 | 40 |
4 1) 2) | M12X150 | 2 | 80 |
5 3) | Mbx12 | 1 | 10 |
1) Bolt with grub screw M8
2) Additionally, a starter for the gearbox.
3) Small flywheel cover.
Pos. A + B. centering sleeves. Gearbox console -A- to gearbox, replace bolts. Screws -arrows- 50 Nm + 90°.
KP to the body, replace the bolts. Bolts -arrows- 40 Nm + 90°.
Lower power unit support, replace bolts. Bolts -A- 50 Nm. Bolt -B- 40 Nm + 90°.
Install cross support -A-. Nut -1- 20 Nm. Bolt -2- 20 Nm.
- Drive shaft to shaft with flange: M10
- Cable stops to gearbox: 23 Nm
- Gear lever to gearbox: 23 Nm
- Slave cylinder to gearbox: 23 Nm
- Bracket connecting tubular-hose line to gearbox: 25 Nm
- Protective cap for drive shaft to engine: 35 Nm
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