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The gearbox will have to removed to replace the clutch.
Disconnect battery earth lead (battery located under the front passenger seat)
Remove the engine cover
Disconnect the air flow sensor multi plug
Disconnect the reverse light switch
Disconnect the earth lead to the gear box
Remove the crank position sensor from the top of the gearbox (this is to protect the sensor from damage)
Remove the top bell housing bolts and starter motor bolts
Slacken the gearbox top mounting centre bolt
Removed the front wheels
Remove the engine under shield
Remove the engine to sub-frame mounting centre bolt
Disconnect the exhaust support bracket from the sub-frame
Unclip the power assistance steering hoses from their support bracket on the sub-frame
Support the steering rack with some cable ties and then undo the 2 securing bolts to sub-frame
Separate the lower suspension ball joints on both sides
Support the sub-frame
Remove the sub-frame securing bolts and lower to the floor
Drain the gearbox oil (remembering to replace the drain plug afterwards)
Remove the O/S drive shaft bearing support bolts and pop the drive shaft out of the gearbox
Pop the N/S drive shaft out of the gearbox and cable tie clear to one side
Remove gearbox closing plate
Remove the hydraulic slave cylinder (no need to disconnect the hose)
Pop the gear selection cables off the selector mechanism and then remove the unit
Disconnect the speedo drive multi plug
Support the engine with a long axle stand (take care not to damage the sump)
support the gearbox with a transmission jack
Undo the top gearbox mounting slackened earlier
Lower the engine and gearbox until the top mounting bolt is clear
Remove the remaining bell housing bolts
Pull the gearbox and out
Lower to the floor
Refitting is reverse of removal, check the clutch environment for any signs of wear or oil contamination, rectifying before fitting the new clutch. Remember to top up the gearbox oil.
Gearbox oil - EP75/80 X 1.8 ltr
What else can I help you with?
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