Removing gearbox

To remove the CP type:

a) preliminary tasks:

- Open the bonnet;

- Disconnect the negative battery cable;

- Remove the cover of the engine;

b) remove the inlet air hose from the air filter (see. Div. "Replacing the clutch slave cylinder" and Fig. 5.13);

c) remove the air filter assembly;

- Remove the two screws (Fig. 5.18);

- Raise the filter and remove the rotary motion;

g) Remove the clutch slave cylinder (see. Div. "Replacing the clutch slave cylinder");

d) remove the flywheel sensor, which is located at the top of the clutch by unscrewing two screws on the sensor and remove the sensor in the direction;

e) disconnect the starter:

- Remove the three screws (Fig. 5.19) in front of;

- Remove the starter motor with adjustable rotational movement of the sleeve;

g) unscrew the fixing screws at the top of the gearbox (Fig. 5.20);

h) set the lifting beam (Fig. 5.21), zachalte engine for lifting eyelets and lift it slightly;

i) disconnect the transmission mount from the body (Fig. 5.22):

- Remove the three nuts supports transmission;

- Remove the bolt bearing on the body;

- Remove both feet;

a) Remove the front mudguard of the engine (Fig. 5.23)

l) Remove the left mudguard of the engine:

- Remove the three screws from the top (Fig. 5.24);

- Remove the left mudguard;

m) disconnect the connection with "weight" of the gearbox by removing the bolt (Fig. 5.25);

n) Remove the heat shield on the right axis, removing the three screws (Fig. 5.26);

a) remove the central longitudinal beam (Fig. 5.27):

- Unscrew the two nuts of the engine mounts;

- Remove the four screws on the central longitudinal beam;

- Remove the two screws from the rubber grommets;

- Remove the central longitudinal beam;

n) Disconnect the rod from the shift gearbox:

- Unscrew the nut 3 (Fig. 5.28) and push the bolt 2 up;

- Tie rod of a gear change;

p) Disconnect the reverse gear switch (Fig. 5.29);

c) Drain oil from the gearbox:

- Remove the bolt and remove the pallet;

- Place the container;

- Remove the drain plug;

- Make sure that the oil into the engine;

- Put the drain plug with a new sealing ring and tighten to 38 N ?� m;

t) Disconnect the flexible shaft of the speedometer from the gearbox:

- Clean the connection (Fig. 5.30);

- Remove the locking pin 2 of the gearbox;

- Gently pull the flexible shaft 1 of a speedometer from a transmission;

- Close the connection hole;

v) remove the front wheel:

- Loosen the bolts of the front wheels;

- Hang out the front wheels;

- Put the support legs;

- Remove the front wheel;

f) Remove the right axle:

- Remove the two locking pin with a mandrel diameter of 5 mm (Fig. 5.31);

- Turn out the top bolt and loosen bottom bolt knuckle;

- Press the knuckle and carry out axle shaft as far as possible from the shaft of the gearbox;

x) Disconnect the left axle:

- Remove the three screws that secure the protective bellows (Fig. 5.32);

- Remove the ABS wire bracket;

- Remove the locking clip and remove the pipe from the brake arm;

- Remove the two adjustment screws and remove the shock absorber from the knuckle;

- Turn the steering wheel all the way to the right;

- Carefully remove the shaft from the gearbox;

- Close the spider hole and transmission;

- Turn the steering wheel to the center position;

c) remove the gearbox:

- Establish a support 999 5972 and secure it under the gearbox (Fig. 5.33);

- Remove the engine mounting bolts connection with manual transmission;

- Lower the engine and transmission so that they do not touch the body by the distributor;

- Remove the gearbox;

h) Remove the items from the old gearbox:

- Support;

- Adjusting sleeve 1 and 6;

- Switch 8 reversing light;

- 4 clutch release bearing, fork 3 and a rubber sealing element 2;

- Remove the pin 5;

- Clean and check the removed parts:

- Check the clutch and pull the plug, as described in Section. "Clutch";

e) set the details in the new transmission;

- Remove the plug and remove the protective cover, move them to the old gearbox;

- Replace the setting sleeve;

- Apply sealant (catalog number 1161099-5) on the reverse gear switch, switch, tightening torque 22 Nm;

- Lubricate the ball bearings with grease the clutch fork Volvo number 1161246-2;

- Replace the clutch, fork and a rubber sealing element;

- Put the pin 5, the torque

50 Nm

- Mount bracket tube hydraulic clutch, torque 48 Nm;

- Put the support with a torque of 40 Nm.