Gearbox (Hydraulic Clutch), Removal

Gearbox (hydraulic clutch), removal

Important Cables, hoses, leads etc. are secured with hard plastic cable ties. When these are tightened, the end is cut off, leaving more or less sharp edges at the fixing points. Be mindful of the risk of injury due to these sharp cable tie ends.

1. Place the car on a lift.






2. Drape wing protectors over the wings to prevent soiling and damage to the paint work.
3. Remove the cover over the intake manifold or resonating chamber with hoses and mass air flow sensor.
4. Disconnect the battery cables from the battery.
5. Remove the battery.






6. Engage 4th gear and remove the plastic plug from the gearbox. Lock 4th gear in the gearbox by inserting locking pin tool 87 92 335.

7. From above, undo the clamp securing the selector rod in the gearbox linkage.






8. Raise the gearbox gaiter. Engage 3rd gear so that the selector rod moves out of the linkage and insert locking pin 87 92 335 in the gear-lever housing.

9. Depress the clutch pedal about 50 mm with a brake pedal clamp. This prevents the brake fluid from running out of the reservoir.






10. Remove the retaining clip adjacent to the slave cylinder and undo the delivery pipe connection.






11. Unplug the connector for the reversing lights.
12. Remove the positive cable's mounting adjacent to the engine.
13. Remove the 3 upper gearbox bolts.






14. Disconnect the electrical lead or leads from the oxygen sensor and remove them from the clip or clips.

15. Take up the weight of the engine and gearbox using lifting beam 83 93 850. Place the beam on the wheel housings so that it rests against the wing edges.

16. Raise the car.
17. Remove the front wheels.
18. Remove any clamps securing the oxygen sensor's lead.






19. Remove the front exhaust system by first undoing the flange and then undoing the rear mounting. It is important to remove the exhaust system in this way as the flexible section could otherwise be damaged. Also be careful with the oxygen sensor or sensors.

20. Remove the air deflectors and the cover in the righthand wheel housing.
21. Remove the end piece, suspension arm on both sides. Use separator 89 96 696.
22. Remove the two nuts securing the rear engine mounting and the two middle subframe retaining bolts.

23. Position lifting trolley 83 94 793 with parent fixture 83 94 801, front holder 83 94 819 and rear holder 83 94 827 under the subframe. Raise the lifting trolley up to the subframe.

24. Remove the remaining subframe retaining bolts. Washers are installed at the rear mountings, be sure to collect them.

25. Lower the lifting trolley and roll it to one side.






26. Remove the drain plug and drain the gearbox oil. Install the plug back in place.
Tightening torque: 50 Nm (37 ft lbs)






27. Withdraw the lefthand drive shaft using dismantling 89 96 654 (Tripod type joint) or 87 92 376 (Rzeppa type joint). Suspend the drive shaft with cable ties and install protective plug 87 92 244 in the gearbox.






28. Remove the splash guard adjacent to the flywheel.
29. Remove the ground leads from the gearbox.

30. Remove the bolts from the engine/gearbox mating surface. The bolts are accessible from below, except the front one.

31. Remove the lefthand engine mounting's two bolts from the body.
32. Detach the bracket from the gearbox.
33. Lower the car and lower the entire power train about 5 cm.






34. Raise the car and install lifting 87 92 608 (MKM 886) in position. Adjust it so that its center is in line with the center and mating face of the gearbox.

35. Install the gearbox using lifting tools on a suitable pillar jack.
36. Remove the last bolt between engine and gearbox.






37. Remove the rear engine-mounting's bracket from the gearbox.
38. Pull out and lower the gearbox.

WARNING: Take care not to tip the jack.

39. Lift the gearbox off the jack and detach the lifting tool from the gearbox.