The gearbox and main gear form one unit, with which the driveshafts are closely related. The box is delivered in four versions- and five-speed gears. The basic structure of both crates is the same, except that the 5-speed gearbox has an extra pair of gears under the tailgate for overdrive. Synchronizer hub for gear 5. and reverse comes from the gearbox reverse synchronizer 4- running gear – this is an example of proper unification!
The repair work concerns the 5-speed gearbox, however, they can also be referred to as a 4-speed gearbox, if overdrive gears are omitted. What may be different for both boxes, are the tightening torques.
Car version 900 ES is different from normal 900 other selection of gear ratios of the gearbox and final drive.
Removal / installation of the gearbox
The gearbox can be removed from the bottom of the car, therefore the vehicle must be driven onto the jack. You can either remove the entire powertrain and then disconnect the engine and transmission, or proceed as described below
■ Unscrew the rear gearbox suspension.
■ Disconnect the power cord for the reverse lamp switch and the speedometer cable.
■ Remove the clutch cable.
■ Raise the drive unit a little.
■ Disengage the suspension on the gearbox.
■ Remove the lower bolts connecting the engine to the gearbox.
■ Unscrew the exhaust pipe bracket from the gearbox.
■ Remove the gearbox side cover.
■ Disconnect the control rods from the gearbox.
■ Unscrew the triangle arm from the body.
■ Disconnect the constant velocity joints from the wheel hub.
■ Attach the driveshafts properly. to prevent the end of the driveshaft from falling out of the differential housing.
■ Remove the starter.
■ Lower the engine a little and brace the gearbox.
■ Remove the sheet metal between the engine and gearbox.
■ Remove the upper bolts connecting the gearbox to the engine and move the gearbox to the side from the engine, until the end of the main shaft exits the clutch hub.
■ Lower the gearbox.
The gearbox is fitted in the reverse order. You should always use new nuts to attach the driveshaft to the wheel hubs, which are tightened with a moment 265 N • m, and then secures.
