Gearbox (page 10 of 11)

70. Remove 3 LH rear and 2 LH front subframe to body mounting bolts.
71. Remove LH rear anti-roll bar bracket from rear mounting.
72. Lower subframe sufficiently to allow gearbox removal.
73. Raise engine on jack until clear of rear subframe LH longitudinal member.

CAUTION: Use a block of wood or hard rubber pad to protect sump.

74. Remove 7 bolts and 1 nut and bolt securing gearbox to engine.
75. With assistance, release gearbox from engine.
76. Remove gearbox between body and subframe.
77. Remove circlips from end of both drive shafts.

Refit

1. Clean mating faces of gearbox and engine; ensure locating dowels are fitted.
2. With assistance, fit gearbox and locate onto dowels.

CAUTION: During the above keep the drive shaft horizontal to avoid damaging oil seal.

3. Fit 7 bolts and 1 nut and bolt securing gearbox to engine. Tighten: - Gearbox to engine 80 Nm - Gearbox to sump 45 Nm.
4. Lower engine on jack until gearbox rests on subframe longitudinal member, remove jack.
5. Raise subframe on jack.
6. Fit rear anti-roll bar mounting bracket to subframe rear mounting.
7. Fit bolts securing front and rear subframe mountings and tighten bolts to: - Rear mounting 45 Nm - Front mounting 30 Nm.
8. Align suspension damper to upper arm, fit ABS sensor lead clip and spacer and tighten nut and bolt to 45 Nm.
9. Fit coolant pipes to floor and tighten bolts to 25 Nm.
10. Fit crossmember. See BODY, Exterior fittings.
11. Ensure union of hydragas pipes are clean and fit new ’O’ ring seal.
12. Connect hydragas pipe and tighten union to 20 Nm.
13. Fit clip to secure hydragas pipe to floor.
14. Fit rear anti-roll bar and tighten bolts to 13 Nm..
15. Fit gear change cable abutment brackets and tighten bolts to 45 Nm.

NOTE: Fit earth cable to upper bolt on lower bracket.