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Removing and installing transmission
Transmission is shot down. This requires a lift platform or 4 reliable support and lift with a suitable gasket for wood lowering transmission. For the suspension remaining on the car engine requires crane. Withdrawal | - Disconnect earth cable from the battery.
 | This data is erased from the memory of malfunctions of the engine or a protective code of a radio receiver. Before disconnecting the battery should read instructions in Section Removal and installation of the battery. |
- Disconnect the battery positive cable, loosen and remove the battery.
- Unscrew and remove the battery holder.
- Petrol engine: Remove air filter, see chap. The power supply system, the carburettor, fuel injection system, Section Removal and installation of the air filter.
 | - The injector and diesel: Remove the intake pipe and pre-chamber intake manifold, this weaken collars and to remove the air hose.
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- The diesel engine: Remove the fuel filter, see. Chapter Introduction.
- Unscrew the cap nut of the speedometer. Remove the speedometer shaft. On vehicles with a 9/89 MY. unscrew the bolt speedometer gear shaft.
 | - Petrol front-wheel drive model to 9/89 MY. and all models "versatile": Disconnect the cable on the clutch lever and unscrew the counter support on the gearbox.
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 | - Hydraulic drive: Unscrew the clutch slave cylinder to the transmission housing (2 screws). Hydraulic lines do not weaken! Remove the supply line of attachment. Hang slave cylinder on the side of the wire to the body.
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- Unplug the reversing light on the gearbox.
- Unscrew the workpiece on the upper side of the gearbox.
- If there are, unscrew the mounting rails and fixing cables coolant pipe on the gearbox casing.
- Remove the starter, for loosening of bolts. Pre-disconnect on the starter cord and the plug. See also Chapter electrical system.
- Loosen the bolts of the front wheels without unscrewing.
- Lift the front of the vehicle.
- Remove the front wheel and unscrew the left side mudguard in wheel arch.
- Drain the transmission oil, see. Chapter Introduction.
 | - Unscrew the two shift rod on the gearbox and hung on wire to the bottom.
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- Remove the left and right drive shafts. To this must be removed first the tie rods, then lower wishbones on both sides. Finally, squeeze the drive shafts on the internal hinge, see. Chapter suspension and steering system, Section Removal and installation of the drive shaft.
- Remove (if present) front stabilizer bar, see. Chapter suspension and steering system.
 | - Trailers for earrings motor cable and pull it a little bit, t. E slightly raise engine.
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 | - Unscrew gearbox from the middle of the beam engine mount. Then unscrew the beam from the body and remove it.
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 | - Unscrew the clutch cover.
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Only four-wheel drive |  | - Remove the cotter pin and remove shift rod to the gear lever. Remove the bracket on the counter support.
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 | - Unscrew the support bracket bolts of the intermediate shaft drive shafts.
- Remove the front exhaust pipe and crossbar in the propeller shaft tunnel.
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 | - Remove the propeller shaft before loosening bolts mark the position of the front and rear flanges felt-tip pen, the shaft can be installed in the same position.
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- Only engines BP - SOHC (motor identification, see chap. Petrol engines): Unscrew the water when the differential lock (4 screws), pre-shift rod turning a screwdriver (performed in the workshop).
- Unscrew the rear engine mount on the body.
- Lower the engine / gearbox using a hoist on the left side.
 | - Unscrew the front engine support on gearbox.
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 | - Set the lift under the gearbox, use suitable wooden spacers.
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- Release 2 available top flange bolts connecting the engine and gearbox. On models 87 MY. (engine E) instead of 2 has four upper bolts.
 | - Remove the underside of the lower bolts of the engine and gearbox. On diesel engines should be further unscrew the 2 corner between the gearbox and the engine from the bottom left and right.
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- Gently lift the gear box and squeeze the hand of the engine mount.
- Lower transmission via the lift and roll out with the help of an assistant.
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Setting | - Before installing gearbox, check the clutch and release bearing, see. Chapter Clutch.
- Clean input shaft splines and lightly grease with a molybdenum paste or spray.
| If there is too much lubricant is applied, during operation, it can get on the driven disc friction lining, causing malfunctions. |
- Gearbox rolled under the car on a lift.
- If you are installing the gearbox input shaft not enter into the clutch disc, turn the shaft a little box (including transfers), or ask the assistant to turn the crankshaft slightly.
- Align gearbox. In most cases, the motor flange has guide pins, which shall enter into the openings in the clutch housing.
- Insert all bolts and secure transmission to the engine. Tighten bolts to 90 Nm.
| Thus in any case not pull the transmission to the engine by means of bolts. All bolts evenly wrap first, only then tighten with a torque wrench. |
- Secure the front support of the engine to the gearbox and tighten bolts to 50 Nm.
- Install the engine using a hoist to the correct installation position.
- Screw the high beam engine mount on the gearbox and tighten 4 bolts -A- with torque of 50 Nm.
 | - Screw the high beam to a body with a force of 80 Nm, the bolts -B-.
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 | - Screw the back support of the engine to the body with a force of 80 Nm.
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- Remove bracket and lift the engine.
- Only four-wheel drive: Align the propeller shaft flanges on labels, insert the bolts and washers and tighten nuts to 30 Nm.
- All-wheel drive: Install the shift rod and the exhaust pipe, if necessary, install the drive differential lock (done in the workshop). See section
- All-wheel drive: Secure the support bracket bolts of the intermediate shaft drive shafts in the above sequence with a force of 50 Nm. See
- Insert the clutch cover and screw it. In the diesel engine further screwed side reinforcing plate.
- Insert the starter and tighten the three bolts to 40 Nm.
- Connect the connector and cable to the starter.
- Set both drive shafts with new retaining rings, see. Chapter suspension and steering system, Section Removal and installation of the drive shaft.
- Install the stabilizer and tips of steering drafts, see chap. Suspension and steering system.
 | - Screw the thrust switch on the gearbox. Tighten the so-called extension rod with a force of 40 Nm, shift rod with a force of 20 Nm.
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- Screw the mudguard of the left wheel arch.
- If so, screw the bottom cover of the engine.
- Fill with transmission oil. See Section Routine maintenance.
 | - Set the tachometer shaft on the gearbox and screw the cap nut. On vehicles with a 9/89 MY. pre-insert speedometer gear and screw bolt -strelka-.
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- Screw the clutch slave cylinder on the gearbox and tighten bolts to 20 Nm. Lay hydraulic lines to the bracket on the gearbox. In an embodiment, a cable operated to attach and adjust the clutch cable, see chap. Clutch, Section Adjustment of a pedal / clutch cable.
- Screw the front wheels and lower the car.
- Tighten the wheel nuts crosswise with torque of 100 Nm.
- Connect the plug to the reversing light switch.
- Screw the earth cable transmission.
- If there is, cable holder and screw fixing coolant pipe on the gearbox casing.
- Set the air filter and air intake hose. See chapter power supply system, the carburettor, fuel injection system, Section Removal and installation of the air filter.
- The diesel engine: Fit the fuel filter.
- Insert and secure the battery holder.
- Install and connect the battery, first above zero, then the earth cable.
- If available, set the clock and set the security code radio.
- As soon as possible to measure the angles of the wheels.
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