Gearbox - ’t’ series (page 5 of 5)

45. Remove 2 bolts securing mounting bracket to gearbox.
46. Lower engine on jack and remove 2 bolts securing mounting bracket to gearbox.
47. Remove mounting bracket from gearbox.
48. Attach hook of crane to gearbox lifting eye and support weight of gearbox.
49. Remove 3 remaining bolts securing gearbox to adaptor plate.
50. Release gearbox from locating dowels.
51. Lower crane to release gearbox from engine compartment.
52. Release hook of crane from gearbox lifting eye.
53. Remove gearbox from beneath vehicle.
54. Remove bolt securing lifting eye to gearbox, remove lifting eye and refit bolt.

Refit

1. Clean mating faces of gearbox and gearbox adaptor plate; ensure locating dowels are fitted.
2. Clean gearbox input shaft and clutch drive plate splines.
3. Remove bolt securing gear case to differential housing, position lifting eye, fit and tighten bolt.
4. Position gearbox beneath vehicle.
5. Attach hook of crane to lifting eye and raise gearbox until aligned with engine.
6. Locate gearbox input shaft to clutch and align locating dowels to adaptor plate.
7. Fit uppermost bolt securing gearbox to engine and tighten to 83 Nm.
8. Fit bolt securing gearbox to adaptor plate located alongside upper coil mounting bracket bolt and tighten to 45 Nm .
9. Fit rear lower gearbox to adaptor plate bolt and tighten to 83 Nm.
10. Detach crane hook from lifting eye and remove crane.
11. Fit mounting bracket to gearbox, fit bolts and tighten to 60 Nm.
12. Raise engine on jack and align engine LH mounting.
13. Fit bolts securing engine LH mounting and tighten to 45 Nm.
14. Remove bolt securing gear case to differential housing, position suitable lifting eye, refit bolt and tighten to 24 Nm.
15. Fit clutch slave cylinder mounting bracket to gearbox, fit bolts and tighten nuts to 70 Nm.
16. Remove jack from beneath engine.
17. Clean LH drive shaft end and differential oil seal.

CAUTION: If a gearbox with modified type differential oil seals is to be fitted to a vehicle that has early type drive shafts, the differetial oil seals MUST be replaced with early type oil seals.

18. Fit NEW circlip to groove in drive shaft and lubricate oil seal running surfaces.
19. Ensuring drive shaft is kept horizontal, insert drive shaft through the seal protector until the drive shaft begins to engage the differential splines.
20. Remove seal protector by pulling carefully on the seal protector tail.
21. Push drive shaft fully home until circlip locks in differential groove. Pull on inner housing to ensure circlip is fully engaged.
22. Clean ball joint and engage ball joint to lower arm, tighten nut to 50 Nm and fit NEW split pin.

NOTE: If necessary, tighten nut only to align next split pin hole.

23. Fit damper fork over lower arm then align to damper.
24. Fit clamp bolt and tighten to 43 Nm.
25. Fit bolt and nut securing fork to lower arm but DO NOT tighten.

NOTE: Bolt to be tightened with vehicle weight on damper.

26. Repeat above operations 17 to 25 and fit RH drive shaft.
27. Fit flat washer to steady bar fixture.
28. Position steady bar and selector rod, align holes.
29. Fit selector rod roll pin and fit retaining clip.
30. Fit steady bar dished washer, fit bolt and tighten to 10 Nm.