Removing
1. Remove retainer (2) and remove the expansion tank (1).
Note. Do not disconnect the coolant hoses.
2. Remove expansion tank (1) to the side.
3. Remove the shift cable from the gearbox.
4. Disconnect the electrical connector (1) from the reverse light switch.
5. Remove the latch (1) and disconnect the front pipe of the clutch slave cylinder (2).
Note. Before disconnecting the front pipe of the clutch slave cylinder, it is necessary to remove the brake fluid from the brake/clutch reservoir. Place a drip tray under the disconnect.
6. Unscrew the three upper bolts securing the gearbox to the engine (1) using tool DT-48783 with socket E18.
7. Raise and secure the car.
8. Install support fixture CH-49290 following the fixture manufacturer's instructions.
9. Remove the power unit with the front suspension subframe.
10. Remove two screws (1) and remove the front support (2) from the gearbox.
11. Loosen the bolts (1) and remove the rear gearbox mounting bracket (2).
12. Drain gear oil.
13. Disconnect the left drive shaft from the gearbox.
14. Remove the intermediate drive shaft.
15. Lower the car.
16. Install tool EN-47649.
17. Unscrew and dispose of the mounting bolts (1) gearbox mounting bracket.
18. Lower the engine and transmission on the left side using tool EN-47649.
19. Remove the mounting bracket from the left side of the gearbox (2). Loosen three screws (1) mounting bracket.
20. Raise the car.
21. Remove the four lower gearbox bolts (1).
22. Remove the bottom bolt and nut (2) gearboxes.
23. Install a new gearbox drain plug and tighten to 20 Nm.
24. Place tool DT-47648 on frame base CH-904 and pre-install supports as shown.
25. Pre-install clutch housing support DT-47648-2 (4) to position 2 on the base plate.
26. Pre-install gearbox housing support DT-47648-4 (2) to position 14 on the base plate.
27. Pre-install left mount DT-47648-5 with rear swingarm gearbox (1) to position A on the base plate.
28. Preinstall right support DT-47648-5 with rear swingarm (3) to the F position on the base plate.
29. Connect holder DT-47648 to the gearbox.
Note. Before reinstalling, loosen all screw connections of the pendulum arm and supports. Using the spindles, adjust the crankcase supports so that they are as low as possible.
30. Align holder DT-47648 under gearbox.
31. Connect pendulum arms (1, 2) to the gearbox.
Note. Align the pendulum arms so that the play is eliminated as far as possible.
32. Place the clutch and gearbox housing supports on the gearbox by unscrewing the spindles.
33. Tighten the screw connections of the supports.
34. Remove the last lower gearbox bolt (1).
35. Disconnect the gearbox from the engine.
36. Lower the transmission using a transmission jack with tool DT-47648 until the transmission can be removed from under the vehicle.
Installation
1. Raise the transmission using a transmission jack with tool DT-47648 and place the transmission on the engine.
2. Install the gearbox lower bolt and tighten to 60 Nm.
3. Remove transmission jack with holder DT-47648.
4. Install the three lower gearbox bolts (1) and tighten to 40 Nm.
5. Install bolt (3) gearbox and tighten to 60 Nm.
6. Install the bottom bolt with nut (2) gearbox and tighten to 40 Nm.
7. Lower the car.
8. Install the left transmission mounting bracket. Install three mounting bracket bolts (1) and tighten to 100 Nm.
9. Raise the engine with gearbox on the left side using tool EN-47649.
10. Install three new gearbox support bolts (1), but do not over tighten.
11. Raise the car.
12. Install the intermediate drive shaft.
13. Install the left drive shaft on the gearbox.
14. Install rear gearbox mounting bracket (2) and tighten the bolts (1) torque 100 Nm.
15. Install the front gearbox mount (2) and tighten the bolts (1) torque 100 Nm.
16. Install the power unit with the front suspension subframe.
17. Lower the car.
18. Tighten three new bolts of the left transmission support (1) torque of 50 Nm, then tighten another 60-75°.
19. Remove tool EN-47649.
20. Install the upper gearbox bolts (1) on the engine and tighten with tool DT-48783 with socket E18 to 60 Nm.
21. Connect the front pipe of the clutch slave cylinder (2) and install the latch (1).
22. Connect the electrical connector (1) reversing light switch.
23. Install and adjust the shift cables to the gearbox.
24. Bleed the clutch hydraulic system.
25. Fill the gearbox with gear oil.
26. Install the battery tray.
27. Make a test drive on the car.
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