Manual gearbox removal

accessibility

Disconnect the negative battery terminal.

Drain :

• The gearbox.

Remove :

• The battery and its tray.

• The air filter casing.

• The front wheels.

• The front bumper.

• The fastening A1 screws (tightening torque 5 daNm).

• The stiffener A2.

• The fastening A3 screws.

• The fastening A4 screws (tightening torque 7 daN.m).

• The fastening screw A5 (tightening torque 9,5 daN.m).

• The schock front cross-member.

accessibility

Unscrew :

• The clamp of the escape pipe coupling B1 (tightening torque 3,3 daN.m).

Disassemble :

• The exhaust pipe B2 (at the flexible pipe level).

Remove :

• The rubber bushing B3.

Fasten with strap(s) :

• The exhaust pipe (at the flexible pipe level).

Remove :

• The bolt B4 (tightening torque 10 daN.m).

• The fastening screw B5 (tightening torque 11,5 daNm).

• The lower torque rod B6.

• The fastening screw B7 (tightening torque 4 daN.m).

• The nut B8 (tightening torque 5,5 daN.m).

• The bracket B9.

accessibility

Remove :

• The drive belt.

• The front/right wheel arch.

• The alternator.

Open :

• The cover C1.

Remove :

• The nut C2.

Disconnect :

• The electrical connections.

Remove :

• The fastening C3 screws.

• The starter C4.

Disconnect :

• The connector C5.

• The hose of the vacuum pomp.

Remove :

• The fastening C6 screws (tightening torque 2 daN.m).

• The vacuum pump C7.

Seal gaskets to be substituted when re-fitting.

accessibility

Disconnect :

• The control C cables on the gearbox.

Remove :

• The fastening D screws.

Put aside :

• The bracket E.

accessibility

Disconnect :

• The connector F1.

Remove :

• The fastening F2 screws.

Disconnect :

• The hoses F3.

Remove :

• The supercharging management (waste gate) solenoid valve.

• The fastening G screws.

Put aside :

• The slave cylinder H of the clutch.

accessibility

Unscrew :

• The speed sensor ( hub bearing ).

Extract :

• The speed sensor.

Remove :

With the tool Br :

• The hub nut J ( first tightening 7 daN.m +55° second tightening 28 daN.m ).

Extract :

With the tool Ex1 :

• The steering ball joint L1 (tightening torque 4 daN.m).

Remove :

• The fastening L2 screws (tightening torque 7,5 daN.m).

• The drive shaft, front left.

• The drive shaft, front right.

accessibility

Disconnect :

• Reversing light switch M.

• The earth cable N.

Remove :

• The fastening Q screws (tightening torque 2 daN.m).

• The casing R.

Seal gaskets to be substituted when re-fitting.

accessibility

Remove :

• The fastening S screws.

• The bracket T.

component removal

Put the tool Sm in place.

Remove :

• The nut V2 (tightening torque 12 daN.m).

• The fastening V3 screws (tightening torque 7 daN.m).

• The gearbox bracket V.

• The fastening V1 screws (tightening torque 5 daN.m).

• The gearbox bracket V4.

• The upper fastening screws W1 (tightening torque 8 daN.m).

Put the tool Vr in place :

Below of :

• The gearbox.

Remove :

• The lower fastening screws W2 (tightening torque 8 daN.m).

• The gearbox.

reassembly

Check there are no leaks :

• At the level of the crankshaft seal.

Check :

• The lack of any impact or scratch on the flywheel .

• The degree of wear of the flywheel.

• The condition of the starter’s crown.

• The clutch diaphragm.

Check that the centering rings (on motor side and on gearbox side) are in good condition and proper position.

Clean :

• The output gearbox shaft.

Lubricate :

• The clutch release bearing.

Replace :

• The output seal of the differential of the gearbox.

Proceed reversing the order of the removal.

Fill-up the gearbox.