Removal and installation of a manual gearbox (Renault Symbol 2)

Attention! This subsection describes the removal of the gearbox as a separate unit, separating it from the engine installed on the vehicle.

Special tool:

• Set of punches for removing guide pins - B.Vi. 31-01
• Subframe support - Mot. 1040-01
• Ball joint puller - T.Av. 476
• Drain plug — - — 22 Nm
• Drive shaft boot bolt - 25 Nm
• Lower ball joint nut - 65 Nm
• Shock absorber support bolt - 180 Nm
• Starter bolt - 45 Nm
• Gearbox support bolt - 62 Nm
• Wheel bolt - 90 Nm
• Steering shaft joint bolt - 30 Nm
• Rear subframe bolt - 105 Nm
• Front subframe bolt - 62 Nm
• Steering rod ball joint nut - 40 Nm
• Engine tie rod bolt - 65 Nm

Removal

• place the car on a lift or overpass;
• remove the protective cover of the power unit;
• disconnect the negative battery cable;
• disconnect the contact connectors from the ECU and the fuel supply switch upon impact, move the wires away from the work area and secure them;
• remove the air filter air intake pipe;
• remove the battery tray;
• disconnect the clutch cable from the gearbox and move it to the side;
• unscrew the two bolts and remove the crankshaft position sensor located at the top in the flywheel area;
• disconnect the ground busbars from the gearbox housing;

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Do not completely remove the top transmission-to-engine mounting bolt - remove the transmission-to-engine mounting bolts, but leave the top bolt hand-tight until the transmission is removed (Figure 4.15);





Lower front nut securing the gearbox to the engine - unscrew and remove the front lower nut securing the gearbox to the engine, remembering the installation of the wiring bracket (Figure 4.16);



Gearbox mounting bolts (B):

• unscrew the two bolts of the support brackets B
• remove the front wheels;
• remove the right front wheel drive shaft (see subsection "Front wheel drive");
• remove the left front wheel drive shaft together with the wheel hub (see subsection "Front wheel drive");
• remove the starter (see section "Electrical equipment");
• disconnect the connectors of the reverse light switch and the speedometer sensor, remove the speedometer sensor;
• remove the intake pipe of the exhaust system;

• remove the gear shift drive rod assembly by unscrewing bolt B (Figure 4.18) and three heat shield mounting bolts to gain access to the gear shift lever support;
• remove the torque rod mounting bolt;

• remove the rear gearbox support (Figure 4.19);

• remove the connecting rod from the subframe and body (Figure 4.20) on the left side;
• remove the clamp between the engine and the gearbox;
• remove the steering gear mounting bolts to the subframe as described in the section "Steering";
• to facilitate removal of the steering gear, if necessary, place a shim between the rear wall of the engine and the firewall to tilt the engine forward;
• disconnect the steering gear and remove it, secure it to the side;
• use a lifting device to lift the power unit;

• unscrew the three bolts securing the support to the gearbox housing (Figure 4.21);
• lower the power unit as much as possible without damaging the coolant hoses;
• support the subframe with a trolley jack, placing a piece of board on the jack head, unscrew the four mounting bolts and lower the subframe to the floor;

• place a trolley jack under the gearbox, unscrew the remaining upper mount of the gearbox to the engine (Figure 4.22) and together with an assistant, remove the gearbox from under the car.

Installation

1. Apply MOLYCOTE BR2 grease to the fork pads and release bearing guide.

2. Insert the fork into the release bearing grooves.

3. Check the fit and correct installation of the gearbox centering rings

4. Connect the gearbox to the engine. Do not allow the engine position to change.





5. To facilitate installation of the gearbox, use the guide pin (C).

6. Install:

• stretcher:
• steering gear;
• exhaust system inlet pipe:
• subframe connecting rod;
• when attaching the front wheel drive shafts to the gearbox, install new spring pins and seal them with sealant;
• check the oil level in the gearbox and take a test drive.