Power unit with drive
1 - gearbox housing; 2 - input shaft; 3 - engine; 4 - secondary shaft; 5 - driven gear of the main gear; 6 - differential
Four speed gearbox
1 - gears of the 4th gear; 2 - input shaft; 3 - gears of the 3rd gear; 4 - gears of the 2nd gear; 5 - reverse gears; 7 – an intermediate gear wheel of a backing; 8 - secondary shaft; 9, 13 - drive shafts; 10 – a lock ring of a power shaft; 11 - driven gear of the main gear; 12 - special convex spring washers; 14 - synchronizer of 1st / 2nd gears; 15 - synchronizer 3rd / 4th gear
The gearbox is removed from under the car.
1. Disconnect the ground wire from the battery.
Attention! To maintain the adjustment of the position of the gear change mechanism, engage fourth gear before removing the gearbox.
2. Support the engine with a hoist and raise slightly.
3. In the absence of a lift, install a beam above the engine compartment and support it on wooden blocks mounted on the front fender troughs. Attach the engine to the beam with wire and pull it.
4. Unscrew the union nut of the speedometer drive and remove the cable.
5. Remove the clutch cable from the clutch release lever.
6. Remove the transmission ventilation pipe from the side member.
7. Unscrew the 2 upper bolts from the gearbox mounting flange.
8. Disconnect the heater hose from the thermostat and hang it with a wire.
9. Raise the vehicle and place it on stands.
10. Disconnect the wires, unscrew the 3 bolts and remove the starter.
11. Remove stretch marks (only engine 1.6 dm3) between engine and gearbox (7 bolts).
12. Unscrew the 2 bolts and remove the clutch housing cover.
13. Disconnect the connector from the reversing light switch.
14. Remove the shift rod spring.
15. Loosen clamping bolt (1) at the end of the gearshift linkage and remove the linkage from the gear selection shaft by moving it away from the gearbox. Using a soft wire, hang the rod on the steering gear. Unscrew the bolt (3) stabilizer mounts (2) to the gearbox and use a soft wire to hang the stabilizer to the steering mechanism.
16. Drain the oil from the gearbox, for which carefully unscrew the retainer (1) gear selection shaft (2 - oil filler plug).
Attention! Under the shaft lock there is a locking pin and a spring that must be removed.
17. Remove both transverse arms, while first unscrewing the mounting bolt on the bracket, and then the nut on the ball joint, holding the Torx bolt from turning with a wrench. The arrow indicates the junction of the transverse lever.
18. Remove ball joint from steering knuckle.
19. Remove both drive shafts from the gearbox and hang them on the steering rods with a soft wire. To do this, insert a pry bar or a screwdriver between the CV joint and the crankcase, and while the assistant pulls the car wheel outward with force, dislodge the drive shaft from the side gear with a strong sharp blow on the end of the mount.
20. Instead of the removed drive shafts, insert plastic or wooden plugs to fix the differential side gears. The diameter of the plugs is 22 mm.
21. Unscrew the 4 bolts of the gearbox front suspension bracket, unscrew the nut, remove the rubber support bolt and remove the bracket.
22. Unscrew the nut securing the rear rubber support of the gearbox, unscrew the 3 nuts securing the support lining and remove the lining.
23. Raise the gearbox with a jack through the wooden spacer.
24. Unscrew the 2 lower bolts on the gearbox mounting flange, slightly raise the gearbox, move it away from the engine until the splines of the driven disc hub disengage from the input shaft, then lower it and get it out from under the car.
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