Gearbox (page 6 of 7)

Refit

1. Clean mating faces of gearbox and gearbox adapter plate; ensure locating dowels are fitted.
2. Using assistance, raise gearbox until it is aligned with engine and then locate on dowels.
3. Fit 2 top gearbox to engine retaining bolts and tighten to 70 Nm.
4. Disconnect lifting chain from gearbox.
5. Remove gearbox lifting eye bolt, remove lifting eye, refit bolt and tighten to 25 Nm.
6. Position LH mounting to gearbox, fit bolts and tighten to 45 Nm.
7. Raise engine and align engine mounting bracket.
8. Fit LH engine mounting, tighten M10 nuts to 45 Nm and M12 nut to 70 Nm.
9. Fit crank sensor bracket to gearbox and tighten nut to 8 Nm.
10. Secure fuel filter to mounting bracket.
11. Remove trolley jack.
12. Clean power steering speed sensor and differential mating faces.
13. Fit speed sensor to gearbox, tighten bolt to 19 Nm.
14. Connect speed sensor multiplug.
15. Connect crankshaft sensor multiplug and secure to bracket.
16. Connect reverse light switch connectors.
17. Fit turbocharger hose to intercooler and tighten clip.
18. Connect turbocharger hose to turbocharger intake pipe and tighten clip.
19. Fit air intake hose to intercooler and tighten clip.
20. Connect air intake hose to inlet manifold intake pipe and tighten clip.
21. Connect expansion tank return pipe to radiator and tighten clip.
22. Fit air intake hose assembly to turbocharger and tighten clip.
23. Connect breather hose to camshaft cover and tighten clip.
24. Position sound deadening pad to engine and secure with bolts.
25. Connect air flow meter multiplug.
26. Refit starter motor. See ELECTRICAL, Repairs.
27. Fit earth lead to gearbox; tighten bolt.
28. Fit lower gearbox retaining bolts and tighten to 70 Nm.
29. Position coolant rail bracket to gearbox mounting plate and tighten bolt.
30. Fit shim, special washer and inner rubber bush to suspension tie-rod.
31. Enter tie-rod in cross-member and connect tie-rod to lower arm, tighten bolts to 105 Nm.
32. Fit outer rubber bush and special washer to suspension tie-rod, fit nut and tighten to 68 Nm.
33. Clean LH drive shaft end and differential oil seal.
34. Fit NEW circlip to groove in drive shaft.
35. Lubricate oil seal running surfaces.
36. Insert drive shaft into differential and push fully home until circlip locks in differential groove. Pull on inner housing to ensure circlip is fully engaged.

CAUTION: Keep drive shaft horizontal to avoid damaging differential oil seal.

37. Engage swivel pin in lower arm and tighten nut to 50 Nm, tighten to align hole. fit a NEW split pin, bend ends over against face of nut and ball pin.

CAUTION: Be careful not to damage the ball joint boot. Tighten nut only far enough to align slot with pin hole. Do not align the nut by loosening.

38. Position damper fork over drive shaft and lower arm. Insert damper into fork so alignment tab is aligned with slot in damper fork.
39. Loosely install the damper pinch bolt, damper fork bolt and NEW nut.

CAUTION: The bolts and nut should be tightened with the vehicle’s weight on the damper.