Transmission - removal and refitting

Manual transmission / Transmission - removal and refitting

Note: The following paragraphs describe how to remove the transmission leaving the engine in situ. However, if work is necessary on the engine as well, the engine and transmission can be removed as one unit then separated on the bench as described in Chapter 2B.

Removal
1 The engine must be supported before the transmission can be removed and it is recommended that a hoist or lifting beam is used. As the transmission is removed from underneath the engine bay, first jack up the front of the car and support it securely on axle stands (see “Jacking and vehicle support”), then apply the handbrake.Take the weight of the engine with the hoist or lifting beam.

2 Remove the air cleaner/throttle body ducting as described in Chapter 4A or B as applicable.

3 Disconnect the battery negative cable and position it away from the terminal.

4 Remove the windscreen washer bottle (see Chapter 12) and place it to one side.

5 Disconnect the clutch cable from the transmission with reference to Chapter 6.

6 Unscrew and remove the engine to transmission bolts that can be reached from the top of the transmission.

7 Remove the starter motor with reference to Chapter 5A.

8 Loosen the clip securing the support bracket to the coolant pipe at the rear of the engine, remove the upper starter bolt if necessary, and move the bracket away from the transmission (see illustration).

2.8 Coolant pipe support bracket location

9 Remove the left-hand front engine mounting bracket by unscrewing the nuts securing it to the transmission, removing the mounting bolt, and removing the bolt securing the earth strap.

10 Working beneath the car, unbolt and remove the cover plate from the clutch housing (see illustration).

2.10 Clutch housing cover plate

11 Disconnect the wiring from the reversing light switch (see illustration)

2.11 Reversing light switch (at-rowed)

1 2 Disconnect the inner ends of the driveshafts from the transmission flanges with reference to Chapter 8 and tie them out of the way.

13 Refer to Chapter 12 and unscrew the collar and disconnect the speedometer cable from the transmission.

14 Unscrew and remove the remaining engine to transmission bolts noting the location of the rear mounting bracket (see illustrations)

2.14a Engine rear mounting bracket

2.14b Removing the rear mounting bracket bolts

15 Unscrew the rear mounting nut and remove the bracket, or leave the mounting on the bracket and remove the mounting bolts (see illustration).

2.15 Removing the rear engine mounting and bracket

16 Remove the screw from the shift rod coupling and ease the coupling from the rod.

The screw threads are coated with a liquid locking agent and if difficulty is experienced it may be necessary to heat up the coupling with a blowlamp, however take the necessary fire precautions. If required, remove the coupling ball from the adapter (see illustrations).

2.16a Disconnecting the shift rod coupling

2.16b Removing the shift rod coupling

2.16c Shift rod adapter and bush

17 Support the transmission on a trolley jack then withdraw it from the engine keeping it in a horizontal position until clear of the clutch. If necessary use a lever to free the transmission from the locating dowels.

Caution: Do not allow the transmission to tilt until it the input shaft is clear of the clutch driven plate, or damage to the plate may occur.

18 Lower the transmission and remove it from under the car.

Refitting
19 Refitting is a reversal of removal, but first smear a little molybdenum disulphide based grease on the splines of the input shaft, and make sure the engine rear plate is correctly located on the dowels. Delay fully tightening the mounting nuts and bolts until the transmission is in its normal position. Adjust the gearchange if necessary (see Section 4).