Attention! Due to the complexity of the gearbox design, as well as the need for special tools and devices, it is recommended that you refuse to repair the gearbox yourself and entrust it to the appropriate workshop.
Attention! The dismantling of the gearbox is carried out from under the car. Removing the engine is not necessary.
1. Turn off the ignition and disconnect the battery.
2. Remove the top protective cover of the engine.
3. Remove the air filter.
4. Remove the battery and its tray.
5. Remove clamps 1 and 2 and disconnect cables A and B from the levers (see illustrations 4.5 and 4.5a). Secure the removed cables with wire so that they do not interfere.
6. Release from an arm In the pipeline A of a drive of the executive cylinder (see illustration 4.6).
7. Remove support A of box suspension 02S, disconnect slave cylinder (see arrows B in the illustration), take it aside and secure with wire to the body. Do not disconnect the hose from the slave cylinder, and do not depress the clutch pedal after removing the cylinder.
8. Disconnect the wire for models with a gearbox «masses» (-) from the point «masses» (-) on the left suspension support of the power unit.
9. Unscrew the upper bolts of the gearbox to the engine, as well as the upper bolt of the starter, and then remove the tanks from the left and right wings.
10. Gearbox 02S. Disconnect plug 1 (see illustration) contact switch for reversing lights, as well as wires 2 and 3 from the starter. After that, unscrew the upper starter mounting bolt, as well as the upper bolts with which the gearbox is attached to the engine.
11. Disconnect the hoses and wires near the engine lifting eye.
12. Fasten the power unit to the hoist and lift it up to relieve the lower bolts securing the box to the engine.
13. Jack up the vehicle and place it on jack stands.
14. Remove the left wheel arch liner.
15. Gearbox 02S. Disconnect all hoses and wires from the box.
16. Remove a protective guard of the right power shaft.
17. Remove the exhaust system from the subframe (see illustration).
18. Disconnect the drive shafts from the flanges on the gearbox and secure them with wire to the hanger.
Gearbox OAN
19. Remove the protective cover And the flywheel (see illustration), if any.
20. Disconnect the suspension support with a torsional vibration damper by unscrewing the bolts A, B and C of the fastening (see illustration).
21. Unscrew the lower bolts 5, 6 and 7 securing the gearbox to the engine (see illustration).
22. Install support 3282 with adjusting plate 3282/46 under the gearbox, which is secured with a nut (see illustration).
23. Screw the stud into the hole on the box instead of the suspension mount bolt with damper and unscrew the remaining bolt that connects the box and the engine.
24. Wring out a transmission from the engine and remove it from adjusting pins.
25. Carefully remove the box from the subframe 1, lower it down and out from under the car (see illustration).
Gearbox 02S
26. Remove the front ride height sensor, if installed, and disconnect the right and left anti-roll bars (see illustration).
27. Unscrew nuts of a finger of a spherical support and levers of a forward suspension bracket (see illustration).
28. Unscrew the bolts B and C and disconnect the suspension support with a torsional vibration damper from the box (see illustration 4.21).
29. Disconnect the steering gear from the subframe and secure it with wire.
30. Remove the subframe along with the box suspension support, anti-roll bar and suspension arms.
31. Unscrew bolts of fastening of the left support of a suspension bracket of the power unit (see illustration).
Attention! The support mounting bolts must be replaced with new ones after their dismantling. The bolts are tightened with a force of 60 Nm followed by a 90°turn.
32. Tilt the power unit just enough to access the gearbox hanger bracket bolts (see illustration).
Attention! The bracket mounting bolts must be replaced with new ones after they are dismantled. The bolts are tightened with a force of 40 Nm followed by a 90°turn.
33. Remove the protective cover And the flywheel, if any (see illustration 4.20).
34. Disconnect from a transmission a support of a suspension bracket of system of release OG, and also disconnect a starter.
35. Install support 3282 with adjusting plate 3282/46 under the gearbox, which is secured with a nut (see illustration).
36. Screw the stud into the hole on the box instead of the bolt of the suspension mount with a torsional vibration damper and unscrew the lower bolts that connect the box and the engine (see illustration).
37. Wring out a transmission from the engine and remove it from adjusting pins.
38. Gently lower the gearbox down and out from under the car.
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