Gearbox - ’k’ series (page 4 of 4)

37. With assistance, carefully release gearbox from IRD and clutch.
38. Lower gearbox to the floor and remove lifting equipment.
39. Remove gearbox from beneath vehicle.

40. Collect flywheel rear cover plate.
41. Remove and discard IRD ’O’ ring.

Refit

1. Clean mating faces of gearbox and cylinder block.
2. Clean dowels and dowel holes.
3. Clean mating faces of IRD unit and gearbox.
4. Lubricate and fit NEW ’O’ ring to IRD unit.
5. Inspect drive shaft seal for damage and renew if necessary.
6. Lightly grease gearbox splines with molybdenum disulphide grease.
7. Locate flywheel rear cover plate.
8. Position gearbox under vehicle and connect lifting equipment.
9. With assistance, raise gearbox and manoeuvre into position.
10. Align gearbox to clutch assembly then locate on dowels.
11. Fit 5 bolts securing gearbox to engine and tighten to 80 Nm.
12. Fit gearbox rear mounting bracket, fit bolts and tighten to 65 Nm.
13. Raise gearbox and locate in rear mounting. Fit through bolt and tighten to 80 Nm.
14. Remove lifting equipment and lifting bracket.
15. Position flywheel front cover. Tighten M10 fixings to 80Nm . Tighten M6 nut to 9 Nm.
16. Fit dowel bolt to rear of gearbox and tighten to 80 Nm.
17. Fit flywheel lower cover plate, align tie rod bracket, fit and tighten bolts to 80 Nm.
18. Position gear change rod, fit NEW roll pin and fit roll pin cover.
19. With assistance, fit IRD unit to gearbox.
20. Fit bolts and tighten to 80 Nm.
21. Fit IRD support bracket and tighten bolts initially only to ensure all mating faces are touching. Tighten in the following sequence: 5 bolts securing support bracket to IRD 50 Nm 1 bolt securing IRD support bracket to PAS pump bracket 50 Nm 3 bolts securing support bracket to sump 90Nm
22. Position tie rod bracket, fit and tighten bolts.
23. Fit clutch slave cylinder bracket and earth lead, fit and tighten bolts to 45 Nm.
24. Connect reverse lamp switch wires.