Required tools and materials:
* Set of keys
* Flat head screwdriver
* Phillips screwdriver
* Pipe wrenches
* Special tools or accessories for transmission removal and installation
* New clutch kit (driven and pressure plates, release bearing)
* New gearbox
* Clutch slave cylinder puller
* Hydraulic press
*Brake fluid
* Gaskets and sealant
Procedure:
1. Preparation:
* Place the vehicle on a level surface and apply the parking brake.
* Disconnect the negative terminal of the battery.
* Remove the air filter and throttle body to access the transmission.
2. Removing the automatic transmission:
* Drain the gearbox oil.
* Disconnect all electrical and vacuum connections to the transmission.
* Disconnect the drive shafts from the transmission.
* Disconnect the starter from the flywheel.
* Disconnect the torque converter from the flywheel.
* Remove the transmission pan.
* Unscrew the bolts securing the gearbox to the engine.
*Using special tools or tools, carefully remove the transmission from the engine.
3. Clutch installation:
* Clean the flywheel and oil pan of any old clutch residue or dirt.
* Install the clutch pressure plate onto the flywheel, ensuring proper alignment.
* Install the clutch driven disc onto the splined shaft of the transmission.
*Tighten the pressure plate bolts evenly to the specified specifications.
4. Gearbox installation:
* Install the gasket onto the engine mounting surface.
* Carefully slide the gearbox onto the splines of the clutch input shaft.
* Tighten the transmission mounting bolts with a torque wrench in the specified sequence and to the recommended torque.
* Connect the starter to the flywheel.
* Install the drive shafts into the gearbox.
* Connect the torque converter to the transmission output shaft.
5. Connecting and filling liquids:
* Connect all electrical and vacuum connections to the transmission.
* Install the transmission pan with a new gasket and tighten the bolts.
* Fill the gearbox with the appropriate manual gearbox oil.
* Replace the clutch slave cylinder with a new one if necessary.
* Pour brake fluid into the clutch master cylinder reservoir and bleed the system.
6. Completion:
* Install the air filter and throttle body.
* Connect the negative terminal of the battery.
* Bring the fluid level in the clutch system to the recommended level.
* Turn the ignition key to the «ON» position without starting the engine, and press the clutch pedal several times to bleed the system.
* Start the engine and gradually release the clutch pedal until the car starts to move smoothly.
* Take a test drive and check the operation of the clutch and gearbox.
Additional tips:
*Follow all manufacturer’s instructions, especially regarding tightening torques.
* Use quality spare parts and fluids.
*If you are not confident in your mechanical skills, have this job done by a professional mechanic.
*After installation, break in the clutch following the manufacturer’s recommendations to ensure proper break-in.