Installing Transmission
Special Tools
- Support tool No. 999 5033, or equivalent
- Lifting beam tool No. 999 5006, or equivalent
- Hook tool No. 999 5045, or equivalent
- Fitting Hook tool No. 999 5460, or equivalent
- Counterhold tool No. 999 5461, or equivalent
- Plug tool No. 999 5488, or equivalent
- Prying tool No. 999 5462, or equivalent
- Transmission Fixture tool No. 999 5463, or equivalent
- Lifting Fork tool No. 999 5534, or equivalent
- Counterhold tool No. 999 5540, or equivalent
- Universal tool No. 999 5972, or equivalent
- Jack tool No. 998 5972-0, or equivalent
- Refer to special tool section for additional tool information. Tools and Equipment
Universal Tool
- Protractor too No. 951 2050, or equivalent
Procedure
1. Put a strap around the throwout (release) bearing fork as in the illustration.
Check that mating flanges on transmission and engine are clean, and that the engine locating sleeves are in place.
NOTE: Do not grease primary shaft or throwout (release) bearing sleeve.
2. Install transmission.
- Line transmission up with engine using jack and transmission fixture.
NOTE: Check that transmission lines up straight with engine, with no breaks in clutch plate center.
- Install the seven bolts and tighten them evenly in rotation. Then tighten to 50 Nm
Remove transmission fixture and jack from transmission.
3. Raise engine and gearbox.
- Wind up lifting hook 999 5460 until distance between lifting bar and sparkplug cover is the same as that noted down earlier (step 8 of Removal). Removing Transmission
- Check that no leads or hoses are trapped.
4. Install rear engine mounting to transmission
- Install mounting to transmission (3 bolts).
Tighten the two rear bolts to: 50 Nm.
Now remove the front bolt again.
- Bolt cover to mounting
- Engage cover with mounting and tighten bolt to: 50 Nm.
5. Install engine mounting with new nut
Install engine mounting locating pin in cover and fit nut, but do not tighten.
Install engine mounting steering gear bolt
- Do not tighten bolt.
- Remove support hook tool No. 999 5045, or equivalent.
Install:
- HO2S lead and clips in cover
- VSS connector and lead.
6. Right-hand drive vehicles only:
- Remove tape from driveshaft and rest shaft on oil pipe.
- Lift subframe to 100 mm from body. Align steering gear and impact absorber to subframe
Install left-hand anti-roll bar bearing and cover and tighten both covers to: 50 Nm.
7. Install subframe.
NOTE:
- Use new bolts (4 x M14).
- Grease bolt threads.
- Be careful when installing steering gear bolts in subframe.
- Starting with the left-hand side, raise subframe and install steering gear bolts in subframe.
- Install bolts to subframe and support plate.
Tighten frame bolts to 105 Nm + 120°, then frame bracket bolts to: 50 Nm.
Use protractor tool No. 951 2050, or equivalent.
- Move jack round to right-hand side, remove existing bolts and repeat Procedure.
8. Remove:
- Lifting hook, lifting beam, supports and lifting lug.
Tighten rear engine mounting splashguard nuts to: 50 Nm..
9. Install:
- Five new nuts on steering gear and tighten to: 50 Nm.
- Subframe front engine mounting bolt.
Now tighten both front and rear engine mountings to 50 Nm.
10. Install:
- Steady-bar bracket to transmission (use new bolts).
Use protractor tool No. 951 2050, or equivalent, and tighten to:
18 Nm + 90° (earlier models, 8 mm)
35 Nm + 60° (later models, 10 mm).
- Oil pipe bracket bolts.
Tighten to: 25 Nm.
Tighten exhaust clamp
Wiggle pipe while tightening.
11. Install RH driveshaft to transmission
NOTE: Take care not to damage driveshaft seal bellows (gaiter).
Install bearing cap and tighten to 25 Nm (18 ft. Lb.).
12. RH drive cars only
Install
- Impact absorber/subframe nuts.
Tighten to: 50 Nm.
Use new nuts
- Impact absorber over steering gear (2 bolts).
Tighten to: 80 Nm.
13. Install LH driveshaft
Check that ABS sensor gearwheel on driveshaft is free of dirt.
Push driveshaft in correctly so that its circlip engages with differential slot.
Check by pushing in driveshaft joint casing carefully.
NOTE: Take care not to damage driveshaft seal or boot (gaiter).
14. Twist MacPherson strut clear and insert driveshaft in hub
NOTE: Apply metal glue part No. 1161370-0, or equivalent to driveshaft splines as shown in illustration.
Use a socket wrench to hold suspension arm down.
Install a NEW driveshaft nut (hand tight only)
NOTE: Grease nut thread and flange
15. Install an both sides
- Suspension arm to ball joint.
Use NEW nuts.
NOTE: Check that ball-joint seating in suspension arm is clean and free of grease.
Tighten nuts in sequence inside to out to: 18 Nm + 120°.
Use protractor tool No. 951 2050.
Apply rustproofing agent to area between ball joint, suspension arm and nuts correctly and precisely.
Use rustproofing agent part No. 1161432-8, or equivalent.
- Link arm to anti-roll bar with NEW nuts, tighten to: 50 Nm.
16. Tighten LH hub center nut
Use counterhold tool No. 999 5461 (with 4 wheel bolts) or 999 5540 (with 5 wheel bolts), and protractor tool No. 951 2050, or equivalent, and tighten to 120 Nm + 60°.
Now remove tool.
Lock center nuts
Using a suitable chisel, tap nut locking flange into driveshaft slot.
17. Install
- Brake pipe/ABS cable brackets on both sides.
NOTE: Check ABS sensor seat is absolutely clean.
- First clean ABS sensor with a soft brush.
Now fit it on wheel spindle and tighten to: 10 Nm.
- Plastic nuts and TORX bolts to inner shield on LH side.
No TORX bolts on later models
18. Install
- Cable pipe on subframe.
- EVAP canister.
Clamp hoses to subframe with clamps
Hook hose to subframe.
- Splashguard under engine (earlier models).
19. Install
- Install front cover and push it home in front.
Push it forwards and upwards at back so the cover locating pins locate in their guides.
Install bolts.
- Wheels.
Check that brake discs and pad contact surfaces are clean.
Grease hub center locating pin in front of pad using rustproofing agent part No. 1161405-4, or equivalent.
Install bolts but do not tighten.
Now tighten alternately to: 110 Nm.
When tightening with socket wrench, use torque sleeve tool No. 1158147-7, or equivalent.
20. Install the five bolts between the transmission and engine and transmission and starter motor
NOTE: Remember coolant hose bracket.
- Tighten transmission/engine bolts to 50 Nm (37 ft. Lb.).
- Tighten transmission/starter motor bolts to 40 Nm (30 ft. Lb.).
21. Install:
- Lead clip(s).
- Ground lead
- Clutch slave cylinder.
- Circlip.
NOTE: Remove temporary strap from throwout (release) bearing carefully to avoid moving fork.
22. Install:
- Backup (reverse) light switch connector.
- Shift lever link plate and locking pin.
- Selector cables in brackets.
NOTE: The outboard bracket and selector cables are marked in yellow.
- Lubricate selector levers with grease P/N 1161241-3.
- Selector cables in brackets.
- The two washers and two clips.
23. Install:
- Ground braid to firewall.
- Bolt and nut to torque arm/steady bar.
NOTE: Use new bolt and locknut.
Locknut P/N:
- 8 mm (earlier models) 948 645-7
- 10 mm (later models) 971 098-9.
NOTE: Locknut included as standard on later models.
Tighten to:
- M818Nmplus120�(13ft.1b.+120�)
- M10 35 Nm plus 90� (26 ft. Lb. + 90�)
24. Turbo models only:
Install:
- Oil coolant hose to engine oil coolant
- TB inlet pipe
- Throttle pulley cover
- Hose and lead to turbocharger (TC) pipe on top of engine
- TO intake pipe.
25. Install:
- Expansion tank.
- ACL bracket bolts.
- Battery shelf.
- ACL timing valve (turbo models only).
- ACL with air intake and connections.
- Battery.
- Control valve hoses. (Cars with EGR valve only.)