Warning. To prevent damage to the gearbox mounts, the connections at the points marked «*» in figures 12.26 and 12.27 should be pre-tightened, and the final tightening should be done after the engine is lowered onto the supports.
Pic. 12.26. Fastening elements for F5MV1 and F5M42 gearboxes from year 2000: 1 - fuel filter; 2 - gearbox support bracket; 3 - gearbox support stopper; 4 - lower bracket of the gearbox support; 5 - transmission control cables; 6 - clutch slave cylinder; 7 - wire connection with «weight»; 8 - crankshaft position sensor; 9 - vehicle speed sensor connector; 10 - reversing light switch connector; 11 - harness connector for control wire and auxiliary wiring; 12 - upper bolts for fastening the gearbox to the cylinder block, 50 Nm; 13 - starter
Pic. 12.27. Fastening elements for F5MV1 and F5M42 gearboxes from year 2000: 1 - brake hose retainer; 2 - wheel speed sensor connector (vehicles with ABS); 3 - ball joint of the tie rod end; 4 - ball joint of the lower arm; 5 - anti-roll bar; 6 - thermal protective casing; 7 - central beam assembly; 8 - left drive shaft; 9 - bearing bracket; 10 - right drive shaft; 11 - receiving exhaust pipe; 12 - rear support of the power unit; 13 - gearbox
Removing
- Disconnect the wire from the negative battery terminal.
- Drink gear oil from the gearbox.
- Remove the bottom protective cover.
- Remove the air filter assembly.
- Remove the battery and its support.
- Remove the air-to-air intercooler hose.
- Remove fuel filter (pic. 12.26).
- To support the engine, install a special tool on the car (motor hoist with manual hoist and traverse) (see fig. 12.17).
- Turn away a nut get a bolt and remove an arm of a support of a transmission.
- Using hydraulic jacks, carefully lift the gearbox, then remove the bolts and remove the gearbox support lower bracket.
- Remove the cotter pins, disconnect the selector and shift cables from the gearbox.
- Remove the clutch slave cylinder and, without disconnecting the hose from it, fix it in a place where it will not interfere with the removal of the gearbox.
- Turn out a bolt and disconnect from a transmission a wire of connection with «weight».
- Disconnect the connectors from the crankshaft position sensor, reversing light switch, and vehicle speed sensor, and the control and auxiliary wiring harness connector.
- Turn out the top bolts of fastening of a transmission to the block of cylinders.
- Unscrew the bolts and remove the starter and, without disconnecting the wires from it, fix it in a place where it will not interfere with the removal of the gearbox.
- Raise the car on a lift.
- Remove the retainer securing the brake hose to the front suspension strut (pic. 12.27).
- On a vehicle with ABS, disconnect the connector from the wheel speed sensor.
- Remove the cotter pin and loosen the nut securing the ball joint pin of the tie rod end to the steering knuckle.
Warnings!
- Do not loosen the nut securing the ball joint pin of the tie rod end to the steering knuckle. To prevent damage to the threads on the ball joint pin, use the special tool MB991113 or MB990635.
- To prevent falling of the special tool MB991113 or MB990635, fix it with a cord on the front suspension strut.
- Install special tool MB991113 or MB990635 as shown in figure 12.19, while making sure that the jaws of the tool are parallel. Turn the special tool bolt to push the ball joint pin out of the steering knuckle, then loosen the nut and remove the ball joint pin from the steering knuckle.
- Loosen the nut, remove the bolt and lower arm ball joint pin from the steering knuckle.
- Turn away nuts and get bolts of fastening of the stabilizer of cross-section stability to the bottom levers. Turn out bolts and remove clips of fastening of the stabilizer bar, then remove the stabilizer from the car.
- Turn out bolts and remove a thermoprotective casing.
- Turn away nuts, get bolts and remove the central beam in gathering.
- Turn away nuts and disconnect a reception exhaust pipe from a final collector.
- Insert a pry bar between the inner CV joint of the left drive shaft and the gearbox and lightly tap on the pry bar to remove the drive shaft from the gearbox (see fig. 12.24).
Warnings
- Use the pry bar very carefully so as not to damage the hinge and the gearbox housing.
- Do not insert the pry bar very deep, so as not to damage the differential seal.
- Do not pull on the drive shaft as this will damage the constant velocity joints.
- Turn out bolts and remove an arm of the bearing of the right power shaft.
- Remove the right drive shaft from the gearbox.
- Together with the hubs and steering knuckles, take the drive shafts away from the gearbox. Do not disconnect the drive shafts from the steering knuckles and hubs.
- Using soft wire, secure the removed drive shafts inside the wheel arches so as to prevent the CV joints from being strongly bent.
- Install special plugs instead of drive shafts so that dirt does not get into the gearbox.
Warning. Replace the differential seal each time the drive shaft is removed.
- Turn out bolts and remove a back support of the power unit.
- Turn out the bottom bolts of fastening of a transmission to the block of cylinders.
- Pull the gearbox away from the engine and remove it from the vehicle. When separating the gearbox from the engine, be careful not to damage the gearbox input shaft, clutch release bearing guide bush, and clutch disc.
Installation
- Installation is carried out in the reverse order of removal, taking into account the following.
- Install the stabilizer bar and tighten the self-locking nut so that the stabilizer mounting bolt protrudes above the nut as shown in figure 12.21.
- Establish a stopper of a transmission so that the arrow on a flange specifies the direction shown in drawing 12.28.
Pic. 12.28 Installing the gearbox retaining flange
- Connect the selector and shift cables to the gearbox and secure them with cotter pins.
- Establish a branch pipe of the intermediate cooler of inflated air.
- Install the battery.
- Install the air filter assembly.
- Establish the lower protective casing of a motor compartment.
- Fill the gearbox with gear oil.
- Check up smoothness and correctness of movement of the lever of a gear change in all positions.
- Check the operation of the speedometer.