Transmission, Removing
Transmission, removing
Special tools:
998 5972 JACK 998 5972 Jack
999 5463 FIXTURE 999 5463 Fixture
999 5972 FIXTURE 999 5972 Fixture
999 7077 Jimmy bar 999 7077 Jimmy Bar
999 7101 Fixture 999 7101 Fixture
999 7102 Lifting yoke 999 7102 Lifting Yoke
999 7103 Lifting beam 999 7103 Lifting Beam
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.
Preparatory work
Ignition off
Ignition off.
Note! Leave the key in the ignition switch.
Disconnecting the battery lead
Remove:
- the battery negative lead.
- the box for the battery.
Removing the steering gear screws
Slacken off the 2 steering gear screws. Leave the screws attached by a few threads.
Remove:
- the front wheels on both sides
- the splashguard under the engine.
Draining transmission fluid
Position a container underneath the transmission. Remove the drain plug (1). Drain the oil. Install the plug with a new gasket. Tighten. see Specifications. [1][2]Manual Transmission/Transaxle.
Removing drive shafts
Remove the drive shafts. Service and Repair
Removal
Removing the sub-frame screws
Remove the 2 screws for the steering gear and the sub-frame
Slacken off the sub-frame 2 front and upper screws at the front edge by 3-4 turns on both sides.
Removing the anti-roll bar
Position 998 5972 JACK 998 5972 Jack together with 999 5972 FIXTURE 999 5972 Fixture in light contact under the sub-frame.
Detach the rubber mountings for the exhaust pipe from the bracket.
Remove the screws at the rear edge of the sub-frame. Remove the screw for the torque rod mounting at the front edge.
Lower the rear edge of the sub-frame a little. Remove the screws for the anti-roll bar that can be accessed from the top.
Remove the anti-roll bar.
Hint: Position the rear edge of the anti-roll bar on the sub-frame and allow it to follow the sub-frame down.
Hanging up the steering gear
Position the hooks in the holes in the firewall on both sides. Secure the steering gear in the hooks using tie straps.
Removing the sub-frame
Note! Note the routing of the heated oxygen sensor (HO2S) cable harness.
Remove the cable harness from the sub-frame and from the mounting on the transmission.
Secure the sub-frame against the fixture plate. Use a retaining strap.
Remove the front screws for the sub-frame.
Lower and remove the frame.
Removing the charge air pipe
Remove the charge air pipe under the engine.
Removing components
Remove:
- the ground lead from the transmission
- the torque rod mounting from the transmission.
Removing engine compartment components
Remove the air cleaner (ACL) module. Service and Repair
Removing the gear selector cable
Caution! Ensure that the cable and sleeve do not crack or break.
Remove:
- the mechanical transmission cables from the levers. Use: 999 7077 Jimmy bar 999 7077 Jimmy Bar
- the mechanical cables from the bracket by moving the sleeves back on the cables. Tie up the mechanical cables
- the connector for the back-up lamp switch.
Removing the bracket
Remove:
- the engine coolant hose bracket
- the holder for the bracket.
Secure the cable harnesses and the hoses to expose the screwed joint for the transmission / engine.
Removing the clutch line
Connect the bleed equipment to the bleed screw. Open the bleed screw. Press the clutch pedal down using a pedal jack. Pull out the locking pin and remove the clutch line.
Tie up the clutch line.
Removing the engine and transmission screws
Remove:
- the starter motor
- the 4 screws for the transmission / engine.
Installing the lifting beam and the lifting hook
Connect 999 7102 Lifting yoke 999 7102 Lifting Yoke to the rear edge of the engine. Secure the screw in the front edge and the screw eyelet in the rear edge.
Position 999 7103 Lifting beam 999 7103 Lifting Beam on the suspension turrets and the front cross member, directly above the left-hand engine lifting eyelet.
Connect the lifting hook for the lifting beam to 999 7102 Lifting yoke 999 7102 Lifting Yoke in a notch that positions the lifting hook directly above the engine.
Lowering the engine and transmission
Remove the screw for the left-hand engine mounting.
Lower the engine. Approximately 75 mm of the screw threads must remain. Also check that there are a few millimeters of play between the crankshaft pulley and the side member.
Note! Check carefully that no hoses or cables are stretched or trapped.
Removing the engine mounting
Remove the mounting from the transmission, 5 screws.
Installing the fixture on the mobile jack and transmission
Install 999 5463 FIXTURE 999 5463 Fixture to 999 5972 FIXTURE 999 5972 Fixture. Use the fixture and plate together with 998 5972 JACK 998 5972 Jack.
Align 999 7101 Fixture 999 7101 Fixture and 7101-1 together with their screws to the fixture and the transmission.
Apply the mobile jack lightly against the transmission.
Removing screws
Remove the remaining 6 screws for the transmission and engine.
Removing the transmission
Note! Ensure that the transmission is taken straight out in relation to the engine.
Note! Lower the transmission slightly when removing so that it will pass the side member.
Remove the transmission.