Remove Transaxle

IMPORTANT: Cables, hoses, leads etc. are secured with hard plastic cable ties. After being tightened, the ends are cut off, leaving sharp edges at the fixing points. Be aware of the risk of injury due to these sharp ends of cable tie.

1. Place the car on a lift.
2. Place wing protectors over the wings to prevent soiling and damage to the paintwork.
3. Remove the front grille.





4. Remove the cover over the intake manifold.
5. Remove the plastic cover from the battery.
6. Detach the battery leads from the battery.
7. Remove the battery.
8. Remove the battery tray.





9. Select 4th gear and remove the plastic plug on the gearbox. Lock the 4th gear in the gearbox by inserting Locking Pin 87 92 335.
10. Remove the clip from above that secures the selector rod in the linkage on the gearbox.





11. Lift up the gaiter. Engage 3rd gear so that the selector rod disengages from the linkage and fit Locking Pin 87 92 335 in the selector lever housing.
12. To avoid brake fluid running out of the brake fluid reservoir, depress the clutch approximately 50 mm using a brake clamp. Alternatively, the brake fluid hose can be clamped using Hose Clamp Tool 30 07 739.





13. Remove the clip by the slave cylinder and disconnect the connection for the delivery line. Refit the clip.





14. Unplug the connector for the reversing lights.
15. Remove the 3 upper gearbox bolts.
16. Fit the Locating Studs 83 92 128 in the engine's upper, outer guide hole.
17. Unplug the electric connection/s for the oxygen sensor.





18. Disconnect the selector linkage by the gearbox.
19. Remove the nut from the rear engine mounting.
20. Undo the 3 bolts securing the rear engine pad using a long 10 mm socket, an extension piece with a ball (e.g. 30 17 613) and an Extension Piece with a 3/8" fitting 82 93 102. Leave on the bolts.





21. Lift the engine and gearbox with the Lifting Beam 83 93 850. Position the beam on the wheel housing so that it is touching the edges of the wings as well as being close to the wing retaining screws.
22. Raise the car.
23. Remove the front wheels.
24. Dismantle the covers in front of and under the bumper.





25. Remove the front exhaust system by first parting the flange against the turbo and then removing the rear mounting. It is important that the exhaust system is removed in this manner since the flex gaiter may otherwise be damaged. Also, be careful with the oxygen sensor(s).
26. Dismantle the stay between the engine mounting and engine.
27. Dismantle the rear engine mounting and engine pad. The gear linkage will follow.





28. Dismantle the screw that secures the torque arm to the subframe.
29. Remove the screws that secure the steering gear.
30. Remove the clips that secure the steering servo delivery line to the subframe.
31. Remove the air filter housing from the subframe.
32. Remove the AC-lines from the plastic clips on the subframe.
33. Remove the engine oil cooler from the charge air cooler (2 screws).
34. Route a Strap 83 95 212 around the radiator core and the radiator member to hold up the radiator assembly.





35. Remove the screws that secure the outer ball joints to the steering swivel member on both sides.
36. Slacken the upper ball joint, on both sides, for the anti-roll bar. Take the strain with a 17 mm spanner making sure that the gaiter does not rotate. If the spanner is too wide to go in between the gaiter and MacPherson strut it must be filed down.





37. Remove the protective cover plate behind the flywheel.
B235R: Remove the bolts between the gearbox and engine oil sump as well as the screws to the protective cover.
38. Remove the 4 screws that secure the rear support plate and the 2 screws on the subframe.
39. Place the lifting trolley under the subframe. Trolley 83 94 793, Parent Fixture 83 94 801, Adjustable Feet 83 95 170, Basic Fixture 83 95 188 and Assembly Fixture 83 95 196.
40. Remove the remaining 4 screws that secure the subframe.
41. Lower the subframe and move it aside. At the same time, remove the front mountings (2) for the steering servo delivery line. Hang up the engine oil cooler on a screw so that the cooler is not in the way during the rest of the work.
42. Drain the gearbox oil.
43. Remove the left drive shaft using the Dismantling Tool 87 92 61. Hang up the shaft with a cable tie.
44. Remove both ground cables from the gearbox.
45. Lower the car.





46. Remove the bolts and nuts from the left engine pad and lift off the pad.
47. Lower the unit so that the gearbox goes clear from the structural member.
48. Remove the gearbox mounting from the gearbox.
49. Raise the car.





50. Fit Lifting Tool 87 92 608 on a pillar-type jack.





51. Connect the lifting tool to the gearbox, adjust the lifting tool so its center is aligned with the center of the gearbox and mounting face.





52. Remove the last 2 screws between the engine and gearbox.
53. Pull out and lower the gearbox.

WARNING: Take care not to tip the jack

54. Lift the gearbox from the jack and remove the lifting tool from the gearbox.