Removal and installation of a transmission (rear axle with diagonal balancer)

Removing

Remove engine (see section "Removal and installation of the engine").

Raise the rear seat.



Remove the frame tunnel cover, cut the retaining wire and unscrew the square bolt. Remove the shift bar connection assembly by moving the shift lever away from the inner lever.

Loosen clutch adjusting nut 1 and remove clutch cable guide from gearbox.

Loosen nut 2 and disconnect wire "masses".

Disconnect wires from starter and remove starter.

Remove the protective rubber cap and disconnect the connector (if there) reversing lights.

Unscrew nut 4 and remove the rubber-metal support from the gearbox.

Unscrew the bolts 5 fastening the axle shafts from the gearbox and hang the axle shafts on the wire.

Unscrew hexagon bolts 6 on gearbox bracket.

Place a jack under the gearbox, raise it slightly, pull it back and remove it together with an assistant.

Installation

Attention! If a new gearbox is installed, it is necessary to loosen the nuts securing its bracket to the rear rubber-metal support and tighten them again only after fixing the front support. Do the same when removing the rear gearbox support. By tightening the nuts in a certain sequence, longitudinal deformation and the resulting premature wear of the rubber-metal bearing can be avoided.

Tighten bolts 6 (see picture) fixing the gearbox supports with a torque of 230 Nm (23 kgcm).

Install the starter, connect the electrical wires to terminals 30 and 50.

Connect the reversing light connector to the switch on the gear lever, tighten the rubber protective cap.

Clean the axle joint flanges on the gearbox. The mating surfaces between the gearbox flanges and the axle shaft flanges must be free of any grease.

Install the axle shafts and tighten the bolts 5 of their fastening to a torque of 45 Nm (4.5 kgcm), without forgetting the spacers.

Install the clutch cable together with the guide on the support, lightly lubricate the cable with grease, tighten the rubber sealing collar and screw on the wing nut.

Slide the shift bar connection assembly onto the frame tunnel, tighten the bolt and secure it with wire.

Attention! Since April 1975, disposable self-locking bolts have been used.

Install the engine.

Check clutch cable guide and adjust clutch pedal free play (see section "Clutch pedal free play adjustment".