Contents: Removal ⇓ Installation ⇓
Removal
Disconnect the cable from the negative battery terminal.
Disconnect the speedometer drive cable from the transmission, the connector from the reverse light switch and, if the model is equipped, the 5th gear switch.
Remove the clutch cable hanger mounting bolts and disconnect the clutch cable from the clutch release lever.
Remove the ground wire mounting bolt and the wiring harness bracket.
Remove the starter.
There are two basic methods for supporting the weight of the engine during crossmember and transmission removal operations. A special support mount that rests on the suspension mounts or a winch can be used to lift the engine. If a support bracket is used, install it first. If using a winch to lift the engine, remove the hood first to increase the working space.
Figure 9.14. Location of the upper bolts (1) securing the gearbox to the engine
Remove the four upper transmission-to-engine mounting bolts (figure 9.14).
Raise the front of the vehicle, support it securely on stands, and drain the transmission fluid.
Remove the front wheels, mudguard panels and disconnect the anti-roll bar links. Remove the oil pan guard plate if equipped.
Remove the lower ball joint and steering knuckle mounting 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 axle gears in place.
Separate the shift adjuster rack from the shift rod and separate the extension rod from the gearbox.
Remove the lower gearbox-to-engine mounting bolts.
Figure 9.15. Removing the crossmember and lower left arm of the front suspension
Loosen the bolt, remove the crossmember and lower the left front suspension arm block (figure 9.15).
Supporting the gearbox with a jack, secure the power unit to the jack.
Figure 9.16. Supporting the engine and using an industrial lift to remove the gearbox
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Remove the two remaining bolts, separate the gearbox from the engine and lower it down out of the car's engine bay (figure 9.16). Do not allow the gearbox to hang on the input shaft when separating the gearbox from the engine. Secure the transmission in case it falls off the jack.
Installation
Apply a thin coat of Moly lubricant to the gearbox input shaft splines.
Raise the gearbox, attach it to the engine and secure it with bolts, tightening them to the required torque.
Connect the extension rod to the transmission and the shift rod to the shift control rack.
Install the lower control arm assembly and crossmember.
Screw in the lower gearbox mounting bolts.
Install the intermediate drive shaft.
Install the left drive shaft.
Connect the lower ball joints and install the nuts and bolts, tightening them to the specified torque.
Connect the stabilizer bar links.
Install the mudguards and front wheels. Install the oil pan protection plate.
Install the starter.
Remove the jack supporting the transmission and lower the vehicle.
Install the four upper transmission-to-engine mounting bolts. Tighten the bolts to the specified torque.
Install the wire harness clips and ground wire mounting bolt, then connect the clutch cable.
Fill the gearbox housing with oil.
Connect the speedometer drive cable and connectors to the reverse light switch and 5th gear switch.
Connect the cable to the negative terminal of the battery.