Removing and installing transmission

1. Disconnect the cable of weight from the battery.
2. Drain the transmission oil. Drain plug is located on the underside of the gearbox.
3. Remove the drive shafts from the gearbox, as described in Chapter Coupling and power shafts. You must observe the safety measures.
4. Disconnect the cable from the clutch release lever. The illustration below shows where the cable is connected to the clutch lever.

In the place indicated by the black arrow, disconnect the cable from the clutch release lever. White arrow points to the front of the vehicle

5 - Disconnect the speedometer cable. 6 - Disconnect the electric wires from everyone in the transmission sensor.

5. Disconnect the cable from the starter motor, unscrew and remove the starter.
6. As shown in the illustration below, disconnect from a transmission shift rod and stabilizer bar.

Removing the rods switch when installed manual gearbox

1 - switching rod 2 - sliding fence

7. Loosen all the exhaust front pipe and remove it.
8. Place a pan under the lift. Put in between the wooden pad to prevent damage to the pallet.
9. Place a second lift a transmission and gently lift it in suspension. You can now remove the bolts and the suspension transmission.
10. Remove the gearbox suspended on the rear side and the left. Remove the suspension on the right side and the back side. The illustration below shows the corresponding suspension.

Both illustrated suspension gearbox must be removed.

11. Loosen the bolt connection of the engine and gearbox. To do this, use the lift to get to the bottom bolt.
12. Remove the transmission from the engine and remove the lift. At the same time, make sure that transmission could not fall from the lift. Also, make sure that it does not come across to any part of the engine and was not based on the input shaft.

1. Before installation, carefully clean the mating surfaces of the intermediate plate back of the engine and clutch.
2. Lightly grease the clutch shaft splines and internal splines of the clutch disc.
3. Set the gearbox on the engine and insert the input shaft in the clutch disc. To do this, you can roll the crankshaft back and forth over the V-belt until slots are aligned. The bolts are tightened only after that between the frame and the engine will not play. Insert and tighten the bolts to the specified torque, which is not the same on all models. Also used screws of different lengths and some bolts hold the engine at a transmission, while others are screwed into the engine from the side of the box.

• In the case of the carburettor engine tighten bolts according to the illustration below. Bolts (A) secure the transmission on the engine bolts (B), attach the engine with the thrust area in the gearbox. All bolts are of different lengths.

Fastening gearbox on an engine with a carburetor embodiment

The length of the bolts "l": 1 - 70 mm 2 - 80 mm 3 - 30 mm 4 - 25 mm Tightening torques: 1 to 3 = 30 - 40 N ??? m all others = 16 - 21 N ??? m

• On fuel-injected engine tighten bolts according to the illustration below. These bolts also have different lengths and tightening torques. Again, some of the bolts holding the transmission to the engine (A), and some of the motor on the gearbox (B).

Transmission fastening to the engine in a version with fuel injection

The length of the screws "I": 1 - 55 mm 2 - 65 mm 3 - 35 mm 4 - 45 mm Tightening torques: 1 and 2 = 70 to 80 N ??? m

4. When tightening the bolts pay attention to different values of the moments. Tighten the bolts evenly in several passes.
5. Set the switch rod and stabilizer bar in accordance with the
6. Pour the oil into a box. Not all versions gearbox oil quantity of the same:

• 5-speed gearbox, petrol engine 2.9 l
• 5-speed, fuel-injected engine 3.5 - 3.7 l

7. Install drive shafts, see chap. Coupling and power shafts.
8. Connect the clutch cable and adjust the pedal play, as described in Chapter Coupling and power shafts.