Gearbox assembly (page 7 of 7)

51. Remove 3 remaining bolts securing gearbox .
52. With assistance release gearbox from engine, lower and remove gearbox from under vehicle.

Refit

1. Clean mating faces of engine and gearbox.
2. Ensure dowels are located in engine backplate.
3. With assistance, lift gearbox onto jack and raise to position.
4. Locate gearbox on dowels, fit top securing nuts and tighten to 47 Nm.
5. Fit gearbox securing bolts and tighten to 47 Nm.
6. Raise engine and gearbox to position.
7. Fit and tighten Allen screw securing gearbox to engine.
8. Position engine rear mounting and mounting bracket.
9. Align bracket to cylinder block.
10. Fit and tighten mounting bracket bolts to 45 Nm. Tighten Torx screw to 45 Nm.
11. Position bump rubber to centre beam and tighten bolts.
12. Remove jack from beneath gearbox.
13. Fit rear mounting bottom nut and tighten to 85 Nm.
14. Position PAS pipes to centre beam and tighten bolts.
15. Position steady bar bracket assembly to engine backplate, tighten bolts to 50 Nm.
16. Align steady bracket to centre beam and cross-member, tighten bolts to 50 Nm.
17. Clean splines of clutch release lever.
18. Clean ’C’ clip and clutch push rod.
19. Fit clutch release lever and secure with ’C’ clip.
20. Apply grease to end of clutch push rod, position push rod to slave cylinder and depress slave cylinder piston with push rod until push rod can be engaged in clutch release lever.
21. Clean oil cooler pipes and unions.
22. Position oil cooler pipes, fit new sealing washers and tighten union bolts to 30 Nm.
23. Align oil cooler pipes, fit clamps and tighten clamp securing bolts.
24. Fit new ’O’ rings, connect hoses to oil cooler pipes and tighten hose unions.
25. Clean exhaust front pipe flanges and fit gasket to intermediate pipe.
26. Position exhaust front pipe to intermediate pipe and tighten nuts to 30 Nm. Connect mounting rubber to front pipe.
27. Fit spacer and tie rod rubbers to front cross-member.