Removal
Place the vehicle on a two-post lift, apply the parking brake, turn off the ignition, and open the hood.
Remove the battery.
Remove the battery tray.
For cars with K4M engine
Remove the intake silencer.
Operations for all vehicle configurations
Remove the ECM.
Disconnect the wiring harness from the gearbox.
Disconnect the wiring harness from the ECM bracket.
Move the engine wiring harness to the side.
Unscrew the two nuts 1, Figure 2-3, securing the expansion tank (spanner).
Figure 2-3 - Removing the expansion tank: 1 - expansion tank mounting nut; 2 - expansion tank
Remove and set aside expansion tank 2 without disconnecting the hoses.
Disconnect connector 1, Figure 2-4, of the ignition system wiring harness from the vehicle speed sensor.
Figure 2-4 - Disconnecting the ignition wiring harness from the vehicle speed sensor: 1 - Wiring harness connector to vehicle speed sensor; 2 - gearbox
For vehicles with JR5 gearbox
Disconnect the joints 1, Fig. 2-5, of the gear selection and shift cables from the gearbox levers 2 (flat head screwdriver).
Disconnect the 3 locks of the gear selection and shift cable housings from the brackets on the gearbox by pressing on the locks from both sides.
Figure 2-5 - Disconnecting the gear selector and shift cables from the transmission: 1 - cable hinge; 2 - gearbox lever; 3 - cable sheath stopper
Disconnect the pipeline 1, Figure 2-6, of the clutch hydraulic drive from the working cylinder 2 by pressing the lock 4.
Figure 2-6 - Disconnecting the clutch hydraulic line from the slave cylinder: 1 - clutch hydraulic drive pipeline; 2 - clutch hydraulic drive slave cylinder; 3 - gearbox; 4 - retainer
Caution! Do not pull the lock, this may cause the hydraulic drive connector to fail. If it fails, replace the pipeline.
Open the brake and clutch hydraulic fluid reservoir cap and drain the brake fluid from the reservoir (technological capacity).
Seal the holes in the pipelines (technological plugs).
For vehicles with JH3 gearbox
Move aside protective cover 1, Figure 2-7, of the gear shift drive rod.
Loosen bolt 2 securing the gear shift rod (replacement head 10, extension, ratchet).
Secure the 3rd gearshift drive rod to the body (technological hook).
Disconnect the clutch cable 1, Figure 2-8, from the clutch release fork 2.
Figure 2-7 - Disconnecting the transmission control rod: 1 - protective cover for gear shift lever; 2 - gearbox control drive rod mounting bolt; 3 - gearbox control drive rod
Figure 2-8 - Disconnecting the clutch cable from the gearbox: 1 - clutch cable; 2 - clutch release fork; 3 - clutch cable sheath stopper
Disconnect the clutch cable from the clutch cable housing stop.
Operations for all vehicle configurations
Remove the front wheels.
Raise the vehicle to a height convenient for work.
Remove the engine crankcase guard.
Unscrew the drain plug in the gearbox housing and drain the oil (1/2 inch internal square key, technological container).
Remove the lower and side mudguards from the front fenders.
Unscrew the three bolts securing the front bumper to the subframe and remove the lower part of the bumper, releasing the subframe (torx T30 replacement bit, extension, ratchet wrench).
Disconnect the left front wheel drive shaft.
Disconnect connector 1, Figure 2-9, of the wiring harness from the reverse light switch.
Figure 2-9 - Disconnecting the wiring harness connector and ground wires from the transmission: 1 - wiring harness connector to the reverse light switch; 2 - "Ground" terminal mounting bolt; 3 - "ground" wire; 4 - gearbox
Loosen the two bolts 2 securing the terminals of the wires 3 "ground" to the gearbox 4 and disconnect the "ground" wires (replaceable head 13, extension, ratchet wrench).
Loosen the two bolts securing the power steering line (if available) to the gearbox and gearbox support and remove the bolts (replacement head 13, ratchet handle).
Disconnect the right front wheel drive shaft from the gearbox.
Figure 2-10 - Disconnecting the wiring harness connector from the K7M engine oxygen sensor control: 1 - connector of the wiring harness of the control oxygen sensor; 2 - clamp; 3 - oxygen control sensor
Disconnect connector 1, Figure 2-10, of the oxygen sensor control wiring harness.
Disconnect clamp 2.
Disconnect the wiring harness connector from connector 1, Figure 2-11, of the diagnostic oxygen sensor.
Figure 2-11 - Removing the diagnostic oxygen sensor: 1 - Oxygen sensor diagnostic connector; 2 - diagnostic oxygen sensor
Disconnect the oxygen sensor diagnostic connector from the mounting bracket.
Remove the catalytic converter.
For cars with K4M engine
Loosen the four steering gear heat shield mounting bolts and remove the heat shield (replaceable head 13, ratchet wrench).
Operations for all vehicle configurations
Loosen the bolts securing the steering gear to the subframe (replacement head 18, ratchet wrench).
Figure 2-12 - Removing the rear engine mount: 1 - rear engine mount support; 2 - bolt for fastening the rear engine mount to the gearbox; 3 - bolt securing the rear engine mount to the front suspension subframe
Hang the steering gear to the car body (technological hooks).
Remove the rear support 1, Figure 2-12, of the engine mount.
Remove the front suspension subframe.
Remove starter 1, Figure 2-13.
Figure 2-13 - Removing the starter: 1 - starter; 2 - nut securing the bracket to the intake manifold; 3 - intake manifold; 4 - bracket for fastening the intake manifold to the cylinder block; 5 - cylinder block; 6 - bracket mounting bolt to cylinder block
Install crossmember 1, Figure 2-14, on the vehicle to support the engine and hang the engine by lifting eye 2 on the flywheel side (crossmember for supporting the engine type RST-500 f. "RANGER").
Figure 2-14 - Installing the engine support beam: 1 - crossbar for hanging the engine; 2 - lifting eye
Unscrew nut 1, figure 2-15, studs securing the gearbox to cushion 2 of the left engine mount (replacement head 16, extension, ratchet).
Loosen three bolts 3 securing bracket 4 of the left engine mount to the gearbox 5 (replacement head 16, extension, ratchet).
Remove the left engine mount bracket from the gearbox.
Figure 2-15 - Removing the gearbox from the left engine mount: 1 - gearbox mounting stud nut; 2 - left engine mount cushion; 3 - bolt for fastening the bracket of the left engine mount to the gearbox; 4 - left engine mount bracket; 5 - gearbox; 6 - gearbox mounting stud
Unscrew three bolts 1, Figure 2-16, of the upper fastening of the 2nd gearbox to the engine (replacement head 13, extension, ratchet).
Figure 2-16 - Upper gearbox mount to engine: 1 - upper gearbox mounting bolt to the engine; 2 - gearbox; 3 - nut of the stud securing the gearbox to the engine
Raise the vehicle to a height convenient for performing the work.
Install the hydraulic transmission stand under the vehicle and move its support part all the way to the gearbox (hydraulic transmission stand type SG-1 "GARO").
Unscrew the four bolts 1, Figure 2-17, of the lower fastening 2 of the gearbox to the engine (replaceable head 13, extension, ratchet handle).
Unscrew the two nuts 3, Figure 2-16, of the studs securing the gearbox to the engine (replaceable head 13, extension, ratchet handle).
Disconnect the gearbox from the engine, lower the support part of the hydraulic transmission strut with the gearbox and remove the transmission strut from under the vehicle (hydraulic transmission strut type SG-1 "GARO").
Figure 2-17 - Lower gearbox mount to engine: 1 - upper gearbox mounting bolt to the engine; 2 - gearbox; 3 - nut of the stud securing the gearbox to the engine
Attention! When removing and installing the gearbox, do not rest the end of the primary shaft on the petals of the clutch pressure spring to avoid their deformation or breakage.
Preparing for installation
Check for leaks through the primary shaft seal; replace the guide tube if necessary.
Replace the differential gearbox flange seals.
Replace the clutch release bearing.
Installation
Before installing the gearbox, make sure that the mounting bushings are present and correctly positioned to ensure that the engine and gearbox are aligned relative to each other.
For vehicles with JH3 gearbox
Apply MOLYKOTE BR2 grease to the sliding surface of the clutch release bearing on the guide sleeve and to the working surfaces of the clutch release fork (consumption rate 2 g).
Place the fork under the tabs on the clutch release bearing.
For vehicles with JR5 gearbox
Caution! Do not apply grease to the primary shaft of the gearbox to avoid failure of the clutch slave cylinder.
Operations for all vehicle configurations
If necessary, center the clutch slave disc (clutch slave disc centering tool Emb. 1518 or Emb. 1780 or 67.7823-9702 L).
Install the gearbox on a hydraulic transmission stand and place it under the vehicle (hydraulic transmission stand type SG-1 "GARO").
Raise the gearbox with a hydraulic lift, insert the gearbox input shaft into the splines of the driven disk and screw on the two nuts securing the gearbox to the engine. Tightening torque of gearbox mounting stud nuts 44 Nm (4.4 kgf·m) (replaceable head 13, extension, ratchet handle, torque wrench).
Install four bolts 1, Figure 2-17, lower mount the gearbox to the engine (replaceable head 13, extension, ratchet wrench).
Install three bolts 1, Figure 2-16, for the upper gearbox mount to the engine (replaceable head 13, extension, ratchet wrench).
Tighten the gearbox mounting bolts to the engine with a torque of 44 N·m (4.4 kgf·m) (replaceable head 13, extension, torque wrench).
Lower the support part of the hydraulic transmission strut and remove the transmission strut from under the vehicle (hydraulic transmission strut type SG-1 "GARO").
Install bracket 4, Fig. 2-15, of the left engine mount support on the gearbox and secure with three bolts 3. Tightening torque of the bolts securing the left engine mount bracket to the gearbox is 62 N·m (6.2 kgf·m) (replaceable head 16, extension, ratchet wrench, torque wrench).
Install nut 1 of the left support mounting stud on cushion 2, while the tightening torque of the mounting stud nut is 62 N·m (6.2 kgf·m) (replaceable head 16, extension, ratchet wrench, torque wrench).
Install starter 1, Figure 2-13.
For cars with K4M engine
Install the steering gear heat shield and secure with the four heat shield mounting bolts. Tightening torque of the steering gear heat shield mounting bolts 21 N·m (2.1 kgf·m) (replaceable head 13, ratchet wrench, torque wrench).
Operations for all vehicle configurations
Install the front suspension subframe.
Install the rear support 1, Figure 2-12, of the engine mount.
Install the steering gear.
Connect connector 1, Figure 2-4, of the wiring harness to the speed sensor.
For cars with K7M engine
Install the catalytic converter.
Connect connector 1, Figure 2-11, of the diagnostic oxygen sensor 2 to the wiring harness connector and install the connector on the bracket.
Connect connector 1, Figure 2-10, of the wiring harness of the control oxygen sensor 3 and install the connector in the holder.
Operations for all vehicle configurations
Install the right front wheel drive shaft.
For cars with K4M engine
Install the power steering line mounting bolts to the gearbox support and to the gearbox. Tightening torque of bolts 21 Nm (2.1 kgf·m) (replaceable head 13, ratchet handle, torque wrench).
Operations for all vehicle configurations
Install two terminals 3, Figure 2-9, ground wires and two mounting bolts 2. Tightening torque of mounting bolts 21 Nm (2.1 kgf·m) (replaceable head 13, ratchet handle, torque wrench).
Connect connector 1 of the wiring harness to the reverse light switch.
Install the left front wheel drive shaft.
Install the lower and side mudguards.
Install the three bolts securing the front bumper to the subframe (torx T30 replacement bit, extension, ratchet).
Replace the transmission drain plug sealing gasket.
Install the drain plug in the gearbox housing and tighten to 22 N·m (2.2 kgf·m) (1/2 inch internal square wrench, torque wrench).
Unscrew the filler plug, pour oil into the gearbox and screw the plug back on. The oil level should be at the lower edge of the filler hole (filling unit for transmission oils of type C-223-1, transmission oil according to the current "Codifier of main and auxiliary materials used in maintenance and repair of LADA cars" K 3100.25100.00018, oil consumption rate: for the JH3 gearbox - 2.8 l; for JR5 gearbox - 2.5 l).
Install the engine oil pan guard.
Remove crossmember 1, Figure 2-14, from the vehicle for hanging the engine (crossmember for hanging the engine type RST-500 f. "RANGER").
For vehicles with JR5 gearbox
Connect pipeline 1, Figure 2-6, of the clutch hydraulic drive to the clutch slave cylinder 2.
Remove air from the clutch hydraulic system.
Install stoppers 3, Figure 2-5, of the gear selection and shift cable casings into the gearbox brackets.
Connect the joints 1 of the gear selection and shift cables to the levers 2 of the gearbox.
For vehicles with JH3 gearbox
Connect cable 1, Figure 2-8, of the clutch drive to the gearbox.
Check the clutch drive adjustment.
Install rod 3, Figure 2-7, of the gearbox control drive and secure with rod mounting bolt 2. Tightening torque of the gear shift rod mounting bolt 28 N·m (2.8 kgf·m) (replaceable head 10, extension, ratchet, torque wrench).
Install protective cover 1 of the gear shift lever.
Operations for all vehicle configurations
Install the front wheels.
Install expansion tank 2, Figure 2-3, on the bracket. Tightening torque of nuts 1 for fastening the expansion tank 8 Nm (0.8 kgf·m) (replacement head 10, ratchet wrench, torque wrench).
Install the wire harness bracket and wire harness onto the transmission.
Install the ECM controller.
Install the battery tray.
Install the battery.
For cars with K4M engine
Install the intake noise muffler.
Operations for all vehicle configurations
Check and, if necessary, adjust the front wheel alignment angles.