- elevated (compared to usual) noise;
- difficult gear shifting;
- spontaneous disengagement or fuzzy engagement of gears;
- oil leakage through seals and gaskets.
In addition, the gearbox is removed to replace the clutch, flywheel and rear engine crankshaft oil seal.
Note. The work of removing and installing the gearbox is very laborious, so be sure to first make sure that its malfunctions are not caused by other reasons (insufficient oil level, defects in the clutch drive, loosening of the gearbox, etc.). The gearbox is quite heavy and has an awkward shape to hold, so we recommend removing it with an assistant.
You will need: keys «at 13», «at 18», flat blade screwdriver.
1. Place the vehicle on a lift or pit.
2. Remove the crankcase protection and the lower part of the left engine mudguard (see «Removal and installation of mudguards and engine crankcase protection»).
3. Drain the gearbox oil (see «Checking the level and topping up the gearbox»).
4. Remove the battery (see «Removing and installing the battery»).
5. Remove the plastic spacer from the battery shelf.
6. Remove the air filter inlet sleeve.
7. Remove the electronic engine control unit (see «Removal and installation of the electronic engine control unit»).
8. Remove the right and left mounting blocks.
Note. It is not necessary to remove the electronic engine control unit and mounting blocks. Their absence facilitates access to the mounting of the left suspension support of the power unit.
9. Loosen the tightening clamp securing the gearbox control rod to its lever...
10.... mark in any way possible (e.g. paint) the mutual arrangement of the rod and the lever, so that during reassembly, the adjustment of the drive is not disturbed...
11.... slide the clamp along the rod...
12.... and disconnect the rod and lever.
13. Press any pointed object on the clamp of the speed sensor wiring harness block...
14.... and disconnect the block.
15. Disconnect the clutch release cable from the clutch release fork and bracket on the gearbox (see «Replacing and adjusting the clutch release cable»).
16. Turn out two bolts of fastening «massive» wires to the gearbox and disconnect the wires.
17. Prying off the retainer of the wiring harness block of the reverse light switch with a screwdriver...
18.... disconnect the block from the switch.
19. Take out a motor plait from the holder on a transmission and take it aside.
20. Remove the two bolts securing the TDC sensor to the clutch housing...
21.... and move the sensor along with the wiring harness to the side.
22. Having pressed the clamp of the block of the wiring harness of the oxygen concentration sensor...
23.... disconnect the block...
24.... and remove the harness block from the holder on the gearbox.
25. Remove the transmission breather hose from the holder.
26. On both sides of the car, remove two bolts securing the front brake calipers to the steering knuckles...
27.... move the calipers to the side without disconnecting the brake hoses from them, and secure in any way possible (for example, by tying it with wire to the front suspension springs)...
28.... disconnect the steering rods from the steering knuckle levers (see «Replacing the outer tie rod end»)...
29.... unscrew the two nuts securing the shock absorber struts to the steering knuckles and remove the bolts from the holes of the knuckles and struts.
Note. Disconnecting the front brake calipers, steering rods and shock absorber struts is necessary in order to be able to disconnect the internal hinges of the front wheel drives from the gearbox without removing the drives themselves.
30. Moving the steering knuckles to the sides, disconnect the internal hinges of the front wheel drives from the gearbox (see «Removal and installation of front wheel drives»).
Attention! When disconnecting the inner hinge of the left front wheel drive from the gearbox, be careful not to drop the hinge rollers into the crankcase of the box if they are weakly seated on the trunnions of the three-pin hinge hub.
31. Remove the starter (see «Removal and installation of a starter»).
32. Turn out four bolts of fastening of an oil case to a coupling case.
33. Remove the subframe (see «Removal and installation of a stretcher»).
Note. In the process of removing the subframe from the gearbox, the rear suspension support of the power unit is disconnected.
34. Turn out two top bolts of fastening of a transmission to the engine.
35. Install under the engine...
36.... and the gearbox are reliable supports.
37. Remove the left support suspension of the power unit (see «Replacement of the left support of a suspension bracket of the power unit»).
38. Turn off two nuts of the bottom fastening of a transmission to the engine at the left...
39....and to the right.
40. Move the gearbox back until the clutch housing studs come out of the holes in the cylinder block. In this case, the input shaft of the box should come out of the hub of the clutch disc.
41. Move the box as far back as possible, remove the support from under it and, tilting the back of the box down, remove it from the car.
Attention! When removing the gearbox, do not rest the end of the input shaft on the petals of the diaphragm spring, so as not to deform them.
42. Establish a transmission and all removed details and knots in an order, the return to removal.
Note. Before installing the gearbox, we recommend lubricating the splines of the input shaft and the outer surface of the clutch release bearing guide bushing with a thin layer of refractory grease. Check how the clutch disc is centered using a special mandrel (see «Removal and installation of clutch»)
43. Fill the gearbox with oil (see «Checking the level and adding oil to the gearbox»).