Contents: Removal ↓ Installation ↓
Clutch release drive
1 – fork release spring; 2 – lock nut; 3 – traction adjusting nut; 4 – cotter pin; 5 – clutch release fork; 6 – pusher; 7 – bolt for fastening the working cylinder to the clutch housing; 8 – clutch release drive slave cylinder
Flexible coupling connecting the cardan shaft to the gearbox
1 – bolts for fastening the cardan shaft flange to the elastic coupling; 2 – nuts of the bolts securing the flange of the secondary shaft of the gearbox to the elastic coupling; 3 – device A.70025; 4 – elastic coupling; 5 – rear engine mount cross member
Removal
1. Place the car over a pit or on a lift, put chocks under the front wheels and lift the rear axle on one or both sides. Release the parking brake and set the gearshift lever to neutral. Disconnect the wires from the battery.
2. Remove the front floor mat and gear shift outer boot, then remove the plastic cover and seal.
3. Press down on rod 32 (see Fig. Transmission) lever and using a screwdriver or some other pointed tool, remove the locking sleeve 36 from the groove on the lever rod and remove the rod.
4. Disconnect the suspension of pipes and mufflers at the rear of the car, and then the muffler pipe from the inlet pipe. Disconnect the clamp securing the inlet pipe to the gearbox. Using the 02.7812.9500 key, unscrew the nuts securing the inlet pipe of the mufflers to the exhaust manifold and remove the pipe downwards.
5. Unscrew the lower bolts securing the clutch housing cover.
6. Disconnect the ground wire from the clutch housing and the wires from the reverse light switch.
7. Disconnect the release spring 1 from the clutch release fork 5 (see fig. Clutch release drive) and remove cotter pin 4 from pusher 6. Disconnect slave cylinder 8 from clutch housing. In this case, cylinder 8, connected to the pipeline leading to the master cylinder of the clutch release drive, remains on the car, which eliminates the loss of brake fluid and the need for subsequent bleeding of the hydraulic clutch release drive.
8. Remove the driveshaft safety bracket. Disconnect the speedometer flexible shaft from the speedometer drive.
9. Put on the elastic coupling 4 (see fig. Elastic coupling connecting the cardan shaft to the gearbox) clamp A.70025 and tighten it. This will facilitate the removal and subsequent installation of the elastic coupling. Unscrew nuts 2 and, turning the cardan shaft, remove the bolts securing the elastic coupling 4 to the flange of the secondary shaft of the gearbox. Lower and move aside the front cardan shaft with the coupling.
10. Using the 02.7812.9500 socket wrench, loosen the bolts securing the starter to the clutch housing and release it.
11. Loosen the clutch housing cover mounting bolts.
12. Disconnect the rear engine mount support from the crossmember, then remove the crossmember while supporting the transmission from underneath.
13. Place a special support on a hydraulic lift under the gearbox housing. Using the A.55035 articulated socket wrench, unscrew the mounting bolts and remove the gearbox together with the clutch housing, moving it toward the rear of the vehicle so as to remove the gearbox input shaft from the front bearing and from the clutch driven disk hub.
Attention! When removing or installing the gearbox, it is strictly forbidden to rest the end of the primary shaft on the thrust flange of the clutch pressure spring, so as not to deform the clutch connecting plates.
Installation
14. The gearbox is installed in the reverse order of removal. Before installation, apply a thin layer of LSC-15 (LITOL-24) grease to the splined end of the primary shaft and center the driven clutch disc with the A.70081 mandrel (see Fig. Centering the driven clutch disc using the A.70081 mandrel).