Removal and Replacement
Removing And Installing Transmission G 86
Tools
Item 1 - 2:
Removing Transmission G86
1. Hold engine in installation position at the transport bracket using safety device No. 10-222A and support device No. 9591/1.
2. Remove diagonal braces and sheetmetal cross member.
3. Remove stabilizer.
Note: To remove the transmission, only one of the two connector tubes (left or right) between the rear muffle and the catalytic converter needs to be removed.
4. Remove rear muffler. Service and Repair
5. Remove rear cross member (V strut).
6. Unscrew suspension for muffler on transmission.
7. Remove drive shafts at the transmission and protect the shaft ends against damage (e.g. using scrap pieces of hose with a diameter of 30 mm).
8. Disconnect plug connection for reversing light switch.
CAUTION: The clutch pedal must not be pressed if the clutch slave cylinder has been removed. Danger of injury from the push rod which can be pressed out of the slave cylinder hydraulically. Affix a warning note in the vehicle.
9. Remove clutch slave cylinder and hang up at the side with hose connected.
10. Disengage shift and selector cables on transmission.
Procedure for vehicles with manufacturing date up to 21 April 1997
NOTE: The shift and cables must not be excessively bent or kinked.
- Remove cotter pins for retaining clips "A" and "B".
NOTE: The transmission shift lever must be removed for removal of retaining clip "A".
- Remove retaining clip "C".
- Unclip upper joint rod.
- Loosen locking screw "F".
- Pull off retaining clips "A" and "B" and pull selector cables out of the ball head.
- Detach the support bracket sleeves "D" and "E" at the support bracket. To do this, press tabs in the direction indicated by the arrow and carefully pull support bracket sleeves out of support bracket.
Procedure for vehicles with manufacturing date from 22 April 1997
- Lever off shift and selector cables using a commercially available removal tool.
11. Place transmission jack under the transmission and fasten fixing strap.
12. Remove transmission support together with left and right hydraulic mount.
A - Transmission support
B - Hydraulic mount
C - Fastening nut M 12
NOTE: Fastening nut -C- (M12) must not be loosened because this will damage the transmission support.
13. Unscrew transmission/engine fastening screws. For screw -5- use polygon wrench.
14. Pull transmission to the rear and lower it carefully.
Installing Transmission G86
NOTE: Install in reverse order.
1. Clean teeth of the drive shaft and grease with a thin coat of Olista Longtime 3 EP (available as spare part).
2. Check that dowel sleeves are seated perfectly in the crankcase.
3. Carefully insert transmission and tighten the fastening screws using the correct tightening torque. For screw no. -5-, use polygon wrench.
4. Install transmission support with left and right hydraulic mount.
Tightening torque: 33 Nm (24 ftlb.)
5. Engage shift and selector cables.
Procedure for vehicles with manufacturing date up to 21 April 1997
- Engage and lock support bracket sleeves "D" and "E" at the support bracket.
- Connect shift and selector cables and push retaining clips "A" and "B" onto the ball head.
- Tighten locking screw "F".
- Clip on upper joint rod.
- Install retaining clip "C".
- Push on cotter pins for retaining clips "A" and "B".
Procedure for vehicles with manufacturing date from 22 April 1997
- Press shift and selector cables into place.
6. Insert clutch slave cylinder and tighten fastening screw.
Tightening torque: 23 (17 ftlb)
NOTE:
The bleeder valve must be opened if the push rod cannot be pushed back manually when the clutch slave cylinder is being installed. Connect a collecting bottle with hose for this purpose.
If the bleeder valve is opened, the clutch system must be bled. If it is not necessary to open the bleeder valve, it is no longer necessary to bleed the system.
7. Set up plug connection for the reversing light switch.
8. Fit drive shafts on the transmission side.
Tightening torque: 39 Nm (29 ftlb.) (screws with M8 thread)
Tightening torque: 81 Nm (60 ftlb.) (screws with M10 thread)
9. Screw suspension for muffler on transmission.
Tightening torque: 65 Nm (48 ftlb.)
10. Install rear cross member (V strut).
Tightening torque: 65 Nm (48 ftlb.)
11. Install stabilizer.
Tightening torque: 23 Nm (17 ftlb.) (M8) or 50 Nm (37 ftlb.) (M10)
12. Install diagonal brace.
Tightening torque: 65 Nm (48 ftlb.)
13. Install mufflers.
14. Check transmission oil and, if necessary, top up.
15 Remove safety device No. 10-222 A and support device No. 9591/1 from the engine.
Tightening Torques
