Removal
The parts that must be removed or disconnected when removing the transmission from the vehicle are shown in Figure I:30.
1. Disconnect the ground wire from the battery.
2. Disconnect the wire from the TDC sensor (if available) and gear shift sensors (Formel model "E").
3. Disconnect the reaction rod from the body and gearbox.
4. Disconnect the speedometer cable from the gearbox.
5. Unscrew the upper starter mounting bolts. Bend back the metal petals.
6. Support the weight of the engine with a lifting mechanism (hoist) or a jack with a wooden gasket.
7. Disconnect the transmission support bracket from the top of the transmission and the body side member.
8. Remove the two upper bolts securing the gearbox to the engine.
9. Remove the square head bolt from the pin of the rod at the gear selector lever and remove the lever.
10. Remove the lower starter mounting bolt, remove the starter and hang it on a wire hook.
11. Disconnect the right drive shaft (see chapter "Front suspension").
12. Remove the three screws securing the clutch housing cover.
13. Remove the lower bolt securing the engine to the gearbox.
14. Disconnect the rear support from the gearbox and body.
15. Disconnect the wires from the reverse light switch.
16. Disconnect the ground wire from the gearbox housing.
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17. Disconnect the left drive shaft and hang it to the side on a wire hook.
18. Place a movable jack with a wooden lining under the gearbox housing, support the weight of the gearbox with the jack and unscrew the front bolt securing the engine to the gearbox.
19. Slide the gearbox off the mounting pins and carefully lower it down (this requires the participation of an assistant).
Installation
The gearbox is installed in reverse order. Please note the following:
1. Raise the gearbox, place it on the mounting pins and secure it.
2. On early models (build date before 12.10.7) make sure that aluminum washers are installed between the support bracket and the gearbox. On later gearboxes, the studs and crankcase casting in this area are reinforced and washers are not installed.
3. Before final tightening of the mount bolts and torque rod, align the engine and transmission assembly. The transmission support bracket should be centered on the body bracket, and the torque rod should be centered on the bracket to which it is attached (see chapter "Engines 1.1/1.3").
4. The square head bolt that secures the shift rod pin can be reused, however if a hex head bolt was installed instead, it should be replaced with a new one.
5. Tighten all bolts and nuts to the torque specified in the section "Technical data".
6. Adjust the gear shift drive as described above.
7. Check the free travel of the clutch pedal, adjust if necessary as described above.
8. Check the oil level in the gearbox and final drive (see chapter "Car maintenance work").
Primary shaft seal
To replace the seal, you need to remove the gearbox from the car.
Please note that gearboxes assembled before 12.08.5 and after 13.08.5 have different seals. The new type seals have six recesses on the end surface.
Unscrew the bolts securing the release bearing guide sleeve inside the clutch housing. Remove the old seal from its seat by pressing it with a screwdriver or pulling it out with a wire hook. Lubricate the edges and outer surface of the new seal with oil and carefully press it into place using a tube (mandrel) of the required diameter. The seal should be 2.5 mm below the housing surface, and it should rest against the flange inside the housing hole.
Semi-axle flange seals (drive shafts)
The flange seals can be replaced without removing the gearbox. Disconnect the drive shaft from the axle flange as described in Chapter "Front suspension", and hang the drive shaft on the wire hook.
Place a pan under the axle flange to collect the oil. Fix the flange with a punch or similar tool as shown in Figure I:29. Unscrew the mounting bolt and remove the axle flange. Pull out the oil seal with a screwdriver or suitable hook.
Lubricate the edges and outer surface of the new oil seal with oil and press it into the seat until it stops. Fill the space between the edges of the new oil seal with universal grease, then install the axle flange and tighten the mounting bolt to a torque of 2.5 kg·m.
The right and left seals are the same, but the flanges are different. The difference between the right and left flanges is shown in Figure I:31.
Check the gearbox oil level and top up if necessary (see chapter "Car maintenance work").
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