Manual gearbox removal

Hub locking tool Br :
  • Ref : 1.870.815.000.

Removal tool of the motor bracket Sm ( -> mounting from above ):

  • Ref : 1.870.595.000 1.870.650.000 2.000.025.400.
Tool for gearbox removal Si :
  • Ref : 1.870.835.001 1.870.847.000/1.
Workshop jack Vr :
  • Workshop jack.
Tool to extract the ball joint Ex1 :
  • Ref : 1.871.000.700.

accessibility

Disconnect the negative battery terminal.

Drain :
  • The gearbox.
Remove :
  • The battery and its tray.
  • The front wheels.
  • 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 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.


© Fluxea 2019