Operation CHARM: Car repair manuals for everyone.

Part 2

Note: Before installing the transmission, clean splines of transmission input shaft and grease lightly, e.g. with Olista Longtime 3 EP.

3. Run transmission in so that the clutch slave cylinder can be assembled.

Note:
^ Do not hang the slave cylinder for the transmission on the hydraulic hose after dismantling but fasten it with cable clips, for example.
^ The clutch pedal must not be depressed when the slave cylinder for the clutch has been removed since the piston may be pushed out of the slave cylinder by hydraulic pressure. A warning panel is to be attached to the vehicle for this reason.
^ Since the hydraulic system for the clutch has not been opened, it is not necessary to bleed the clutch.





4. Fit clutch slave cylinder and tighten screws.








5. Carefully move transmission in fully and screw in and tighten fastening screws.











6. Fit transmission support.








7. Install transmission holder.
8. Remove the support from under the engine.
9. Release retaining strap and remove transmission jack.

Assembly work

Note: Protect drive shafts against mechanical damage (e.g. with a rubber hose which has been cut open).








1. Fit drive shafts on the transmission side. To do this, screw in the six Allen screws joining each drive shaft and transmission flange and tighten screws. In order to stop the wheel being pulled round, it should be held still.








2. Engage shift -1 - (grey end piece) and selector cable -2- (blue end piece) into support bracket for transmission and press end pieces onto ball heads.





3. Fit the electric cable (positive lead). Do this by fitting the holder on the transmission -Arrows- and connecting cables in the B-Plus box -1 -.








4. Establish electrical connection to the reversing light switch.








5. Fit the coolant hoses and container.





6. Remove the cross member

Subsequent work

1. Check transmission oil and, if necessary, top up.
2. Fit underbody panels.
3. Lower the vehicle.
4. Connect the battery.