Gearbox assembly (page 8 of 9)

76. Remove top bolt securing gearbox to engine.
77. Move LH drive shaft clear of gearbox.
78. Release gearbox from 2 dowels.
79. Manoeuvre and lower gearbox to floor.

Refit

1. Raise gearbox, align to dowels and secure to engine.
2. Fit top bolt securing gearbox and tighten to 45 Nm.
3. Position engine front mounting ensuring bracket location pip is at the front.
4. Fit mounting bracket to mounting, align bracket to gearbox, fit bolts and tighten to 85 Nm.
5. Align mounting to crossmember, fit bolts and tighten to 45 Nm.
6. Align coolant pipe to crossmember, fit bolts and tighten to 25 Nm.
7. Align rear engine mounting bracket to gearbox. Fit bolts and tighten to 45 Nm.
8. Disconnect chains.
9. Remove bolt securing lifting bracket. remove bracket, refit bolt and tighten to 45 Nm.
10. Remove trolley jack.
11. Position rear steady bar bracket.
12. Fit bolts securing steady bar and tighten to 85 Nm.
13. Fit steady bar and fit bolt securing steady bar to body.
14. Align steady bar to bracket, fit through bolt and special nut. tighten both bolts to 85 Nm.
15. Secure harness clip to bracket.
16. Position coolant pipe to bracket, fit and tighten bolt to 10 Nm.
17. Fit bottom bolt securing gearbox and tighten to 45 Nm.
18. Position crankshaft position sensor heatshield, fit bolts and tighten to 45 Nm.
19. Fit plain washer, dished washer, spacer and bush to tie rod.
20. Fit tie rod, fit bolts securing tie rod to lower arm and tighten to 170 Nm.
21. Fit outer rubber and dished washer to tie rod, fit nut and tighten to 90 Nm.
22. Clean ends of drive shafts and fit new circlip to each shaft.
23. Smear both differential oil seals with engine oil.
24. Engage drive shafts in differential and push fully home. Pull joints to ensure circlips have fully engaged and shafts are retained.

CAUTION: Keep drive shafts horizontal to avoid damaging differential oil seals.

25. Clean lower ball joint tapers and check to ensure boots are not damaged.