How to remove the gearbox? (2101..07)

(Szerző: z. (Houdek Zoltán), utoljára módosítva: 2007.01.15.)

"if the following description is not detailed enough for you, you are advised not to start it alone."

The process in a nutshell is as follows.

First of all:
- disconnect battery leads ("-" first!) because the starter motor will be moved, and there is constant +12V on its main cable without any fuse and insulation.
- prepare jack (a hydraulic one if possible), safety supports, tools, etc.
- Clutch housing is too high to pull off from under the car. You can not do the removal on a flat surface. A pit is definitely needed.

- if there is a plastic console above the gearbox tunnel, remove it
- remove anything around the gear lever (including the plastic cover held by 3 screws)
- remove gear lever from the stick (with 2 small screwdrivers)
- put it in 1st or 3rd gear

Engine bay:
- remove starter motor held by 3 screws
- remove dust cover's fixing bolts (10mm spanner)

From under:
- remove the hydraulic cylinder of the clutch
- remove the ground cable
- after removing the 4 bolts connecting the propeller shaft to the differential, disconnect them
- remove the propeller shaft's bearing + its crossmember from the chassis
- simply pull the propeller shaft out of the rubber donut assembly at the gearbox end
- push the whole prop.shaft (now it is set free) to the rear
- remove the exhaust system. for experts it may be enough to undo the 4 nuts of the Y-pipe and disconnect it from the exhaust manifold.
- disconnect speedometer cable
- disconnect cable of reverse gear switch
- support the gearbox !!!
- remove the gearbox mounting console from the chassis (two nuts)
- remove the 4 bolts connecting engine and gearbox. you can undo these bolts from the engine bay or from under as you like it. 19mm spanner.
- pull the gearbox off the engine, while:
- take care not to let it rest on the input shaft! support it while it is not totally disconnected! (Otherwise it can fall off, cause injury and/or break parts of the clutch assembly).
- lift it to the ground.

Assembling is the same process in reverse order, including neccessary greasing on the clutch fork, and gearbox input shaft. This latter is needed for easier connection when putting it back on. The shaft should be also greased at the clutch bearing's whole travel. Grease the connecting surfaces of the clutch fork.

It is advised to replace old clutch bearing. It can be easily taken off: just pull it off the shaft, the fork will let it run. Put on the new one and be sure to apply the clamps of the fork under the bearing retaining wire spring. Also connect it to the clutch fork stand correctly. This stand is a bolt with spherical head layout.

A few questions:

Q: what about the clutch, I'm afraid it will fall apart!
A: clutch will not fall off or fall apart. it is bolt on the flywheel. nor will the clutch bearing fall off, it is held by the clutch fork.

Q: what models can be replacement?
A: all "classic" (rear-wheel driven) gearboxes are bolt-on interchangeable, with the following restriction: factory-default 5-speed gearboxes have different mounts. The engine connection is the same, the length is the same, the console nut holes are the same, but the rubber mount and the crossmember is different. After buying such a mount+crossmember, the 5-sp gearbox can be easily fitted in the place of a 4-speed.

Q: what are the gearbox ratios?
A: they are described here. Hope you already found it.

Q: what about the oil?
A: you have to use standard (i.e. cheap) transmission oil. Agip Rotra is recommended by mailing list members. Set the gearbox on a solid, flat surface, undo the fill-in plug on the side. Use flexible pipe for the filling. It is enough when the level of the oil reaches the plug's level.

Q: how do I replace clutch disc?
A: undo the clutch bolts from the flywheel. The clutch assembly and disc will fall off. Put the new disc under the clutch mechanism and start to tense the bolts. Stop when the disc is already held by the clutch, but it is still movable. Move it to the center. Be sure to centralize it with your finger (wrong solution) or by any wooden or metallic stick with a close diameter (better solution) or a cut-off gearbox shaft end (best solution). Now fix the bolts and you're OK.