Required tools and materials:
*Manual transmission
* Clutch with release bearing
* Flywheel
* Cardan shaft
* Gear shift lever
* Cable or hydraulic shift system
* Muffler
* Electrical connectors and wires
Instructions:
1. Preparation:
* Disconnect the battery.
* Drain the transmission fluid.
*Remove the air filter.
2. Removing the automatic transmission:
* Disconnect the driveshaft.
* Disconnect all electrical connectors and wiring.
* Disconnect the shift cables or hydraulic lines.
* Unscrew the bolts securing the gearbox to the cylinder block.
* Remove the automatic transmission.
3. Flywheel installation:
* Install a new flywheel on the crankshaft.
*Tighten mounting bolts to specifications.
4. Installation of manual transmission:
* Fit the manual transmission onto the cylinder block.
* Install the gasket and mounting bolts.
*Tighten mounting bolts to specifications.
5. Clutch installation:
* Install the release bearing on the transmission input shaft.
* Install the clutch driven disc onto the flywheel.
* Install the clutch pressure plate and tighten the bolts.
* Adjust the free play of the clutch pedal.
6. Installing the cardan shaft:
* Install the propeller shaft and secure it.
7. Installation of the gear shift lever:
* Install the gear shift lever and secure it.
* Connect the cables or hydraulic shift system.
8. Muffler installation:
* Install the muffler as required.
9. Electrical connection:
* Connect all electrical connectors and wiring.
10. Refilling with liquids:
* Fill with transmission fluid.
11. Checking operation:
* Connect the battery.
* Start the engine and check the operation of the manual transmission.
Notes:
*This installation is complex and requires special Kenntnisse and skills. It is recommended to have this work done by an experienced mechanic.
* The installed manual transmission may affect vehicle performance such as fuel consumption and acceleration.
*The vehicle’s Electronic Control Unit (ECU) may need to be reconfigured to match the new manual transmission.