Removing
Disconnect the wire from the negative battery terminal.
Disconnect the speedometer cable from the transmission, the connector from the reverse light switch and, if equipped, the 5th gear switch.
Remove the clutch cable hanger bolts and disconnect the clutch cable from the clutch release lever.
Loosen the wire fixing screw «masses» and wire harness bracket.
Remove the starter.
There are two main ways to support the weight of the engine during cross member and transmission removal operations. You can use a special support mount that relies on suspension mounts or a winch to lift the engine. If a support mount is used, install it first. If a winch is used to lift the engine, first remove the hood to increase the working space.
Pic. 9.14. Top bolt location (1) gearbox attachment to engine
Remove the four upper bolts securing the gearbox to the engine (pic. 9.14).
Raise the front of the vehicle, secure it on stands and drain the gearbox oil.
Remove the front wheels, mudguard panels and disconnect the anti-roll bars. Remove the oil sump guard plate, if installed.
Remove the lower ball joint and steering knuckle connecting bolts, then separate the lower front suspension arms from the steering knuckles.
Separate the left drive shaft from the gearbox.
Remove the intermediate drive shaft. Insert a wooden plug or similar plug to hold the differential side gears in place.
Separate the shift adjusting rack from the shift rod and separate the extension rod from the gearbox.
Loosen the lower gearbox-to-engine bolts.
Pic. 9.15. Removing the cross member and the lower left arm of the front suspension
Remove the bolt, remove the cross member and lower the left front suspension arm assembly (pic. 9.15).
While supporting the transmission with a jack, secure the power unit to the jack.
Pic. 9.16. Supporting the engine and using an industrial jack to remove the gearbox
Remove the two remaining bolts, separate the gearbox from the engine and lower it down from the engine compartment of the car (pic. 9.16). Do not allow the gearbox to hang on the input shaft when separating the gearbox from the engine. Secure the gearbox in case it falls off the jack.
Installation
Lightly coat the splines of the transmission input shaft with Moly lubricant.
Raise the gearbox, attach to the engine and secure with bolts, tightening them to the required torque.
Connect the extension rod to the gearbox and the shift rod to the shift control rack.
Install the lower arm assembly and cross member.
Screw in the bottom bolts of fastening of a transmission.
Install the intermediate drive shaft.
Install the left drive shaft.
Connect the lower ball joints and screw in the nuts and bolts, tightening them to the required torque.
Connect the anti-roll bar links.
Install mudguards and front wheels. Install the oil pan protection plate.
Install starter.
Remove the transmission jack and lower the vehicle.
Screw in the four upper bolts securing the gearbox to the engine. Tighten the bolts to the required torque.
Install the wire harness brackets and wire retaining bolt «masses», then connect the clutch cable.
Fill the gearbox housing with oil.
Connect the speedometer cable and connectors to the reverse light switch and 5th gear switch.
Connect the wire to the negative battery terminal.