Note: The description is given on the example of manual transmission "02Q".
1. Details of installation of components of a drive of a gear shift are specified on resist. illustrations. Apply grease G000 450 02 to friction points.
4.1a Installation details of the handle and boot
1 Grip with boot, can only be replaced together (the cover plate can be separated from the handle with a screwdriver)
2 duster
3 Clamp for fastening the handle to the lever, to be replaced
4.1b Gear lever assembly installation details
1 Base plate with curved legs, to be replaced
2 Seal, to be replaced
3 Gearshift lever, can be removed/installed without removing the guide
4.1c Details of installation of manual transmission cables
1 Gear selection cable, connects to lug 15
2 Groove selection cable, connects to lug 11
3 Cable bushing 2
4 Lock washer, to be replaced, do not damage the cable when removing
5 Gear lever housing
6 Holder bolts 7, 2 pcs., 20 Nm
7 Metal or plastic cable holder
8 Holder sleeves 7
9 spacer
10 Holder nut 7, 20 Nm
11 Cable end 2 on lever 12 (diameter for metal // plastic lever - 8 // 10 mm), can be installed together with lever 12
12 Metal or plastic slot select lever; the metal one is located in bushings 13 and secured with washer 14, and in the case of a plastic lever, bushings 13 and washer 12 are not used
13 Sleeves for metal lever 12
14 Lock washer metal lever 12, to be replaced
15 Sliding shoe
16 Selector lever, with balancing weight, inserted so that the missing tooth is aligned with the selector shaft
17 Nut, 23 Nm, to be replaced
18 Rope end 1 (diameter 8.5 mm), on lever 16
Removal and installation of the handle with anther
2. Carefully pry up the boot (And on the opposite illustrations) together from the center console around the perimeter using wedges T30098. Turn the boot inside out through the handle
4.2 Separating the boot from the center console
3. Loosen clamp (see resist. illustration) and remove the handle together with the anther from the lever.
4.3 Removing the handle with boot
4. Installation is carried out in the reverse order. The handle should lock into the round groove on the lever. Use a new clamp.
Removal and installation of the plastic lever of a choice of a groove
5. Remove cable lock in handpiece. To do this, slide the sleeve as far as it will go in the direction of the arrow (1 per resist. illustrations) and turn it all the way in the direction of the arrow (2).
4.5 Removing the fixation of the groove selection cable in the tip
Note: In order not to damage the gear selector cable, the lug must be separated from it before removing the slot selector lever. The gear selector must be in the neutral position. The handpiece can only be removed/installed with the lever removed (see subsection below).
6. If lever (And on the opposite illustrations) is attached to the cover with a holder, gently press it until it stops in the direction of the arrow (1) and by moving the lever back and forth in the direction of the arrow (2), pull it out together with the tip (IN) cable in the direction of the arrow (3).
4.6 Removing the groove selection lever (option 1)
7. If lever (From to resist illustrations) fastened to the lid (A), release this lock, and remove the lever together with the tip (D) cable. If the cable cannot be removed, it may be necessary to remove the manual transmission console (E).
4.7 Removing the slot selection lever (option 2)
8. Installation is carried out in the reverse order. Pre-lubricate the rubbing surfaces with G000 450 02 grease. Removal and installation of a tip of a cable of a choice of transfers
9. Remove the slot select lever (see subsection above), insert a screwdriver (And on the opposite illustrations) between bushing (IN) and lever and squeeze out the tip.
4.9 Removing the gear selector cable end
10. With the lever removed, slide the tip onto the lever until the lock pops up (4 in illustration 4.6). The tip should fit freely on the lever.
Removal and installation of assembly of the lever of a gear change
11. Disconnect the negative cable from the battery.
12. Remove the handle and gearshift boot (see paragraphs 2-3). If present, remove the soundproofing.
13. Remove the ashtray (see chapter 11).
14. Give nuts of fastening of assembly of the lever of a gear change (see resist. illustration).
4.14 Lever Assembly Mounting Nuts
15. Remove the air cleaner (see chapter 4).
16. Remove retaining ring (3 on resist. illustrations) gear selector cable from the gear selector lever (1) and remove the cable from the pin (arrow). On models with a metal lever (2) select the groove, remove the retaining ring (4) groove selection cable and remove the cable from the pin (arrow).
4.16 Separating the tips from the levers
17. On models with a plastic slot selection cable, remove the cable lock in the tip and remove the plastic lever along with the tip (see paragraphs 5-7).
18. Give fasteners (see resist. illustration) and remove the cable holder from the gearbox. If available, remove the soundproofing under the engine compartment (see chapter 11).
4.18 Fixing the cable holder
19. Remove the bottom covers on the left and right (see resist. illustration).
4.19 Fixing the bottom cover
20. Remove the cross member (1 per resist. illustrations) central tunnel. Loosen the double clamp (arrows) and separate the exhaust system. Support the front exhaust pipe, unhook the rear muffler (2) from the hangers and remove it. Remove the intake manifold from the exhaust pipe.
4.20 Fastening of the double clamp and the cross member of the central tunnel
Note: Do not bend the flexible section of the exhaust pipe more than 10°.
21. On AWD models, remove the propeller shaft heat shield and propeller shaft (see chapter 8).
22. Remove the heat shield under the selector lever assembly, tilt the assembly down and remove it along with the cables. The following describes the installation.
23. Apply to fingers (arrows in illustration 4.16) leverage (1 and 2) a little grease G000 450 02 and fasten the cables to them with new lock washers (3 and 4).
Note: The plastic slot selector lever does not use a retaining ring, simply clip the cable onto it.
24. Align the lever assembly parallel to the body (the distance to the body must be the same on both sides) and tighten its fasteners.
25. Further installation is carried out in the reverse order. Before installing the air cleaner, adjust the cables (see relevant subsection below).
Removal and installation of cables
26. Remove the shift lever assembly (see subsection above), bend the legs with a screwdriver (see resist. illustration) and remove the lever assembly cover as well as its seal.
4.26 Lid fixing tabs
27. Remove lock washers (2 and 3 on resist. illustrations) and wring out the cables from the lever assembly with a screwdriver.
4.27 Cables on the lever assembly
28. Remove the tips from the cables. To do this, slide the sleeve as far as it will go in the direction of the arrow (1 per resist. illustrations) and turn the sleeve until it stops in the direction of the arrow (2) until audible fixation.
4.28 Removing the fixation of the gear selection cable in the tip
29. Remove the clips (1 and 2 on resist. illustrations) and remove the support from the cables.
4.29 Rope clamps
30. Installation is carried out in the reverse order. Finally, adjust the gearshift drive (see relevant subsection below).
Disassembly and assembly of the shift lever housing
31. Remove the shift lever assembly and remove the cables from it (see subsection above).
32. Lift the top edge (And on the opposite illustrations) springs above the paws of the groove selection lever. Press the screwdriver on the paws (arrows) hinge socket towards the hinge of the arm guide. If necessary, break the tabs of the hinge socket.
4.32 Preparing to remove the hinge socket
33. Pry off the hinge socket (And on the opposite illustrations) together with lever guide and lever (IN) and separate from the shift lever assembly. Then press the hinge socket away from the lever guide hinge and remove it.
4.33 Removing the hinge socket
34. Move the lower edge of the spring to the shoulder on the groove selection lever in the direction of the arrow (1 per resist. illustrations) all the way. Pull the lever guide up to the stop and pull the pivot pin out of the lever in the direction of the arrow (2). Pay attention to guides (A), - they must not be broken.
4.34 Removing the hinge
35. Rotate the lever guide in the direction of the arrow (1 per resist. illustrations) and tilt it together with the lever in the direction of the arrow (3). Hairpin (2) should be in a groove in the shift lever housing.
4.35 Removing the lever
36. During assembly, the lower end of the spring (1 in illustration 4.34) may come off the groove select lever arm. Therefore, you should carefully press the spring from the shoulder down. The ends of the spring are pulled diagonally with a loud noise.
37. Loosen ends (A and B on resist. illustrations) springs, turning them to the right - they should be facing in opposite directions.
4.37 Spring setting position
38. Install the lever guide with the lever into the shift lever housing. Rotate the guide in the direction of the arrow (2 to resist. illustrations), to hinge pin (A) located above the groove in the gear lever housing. Hairpin (1) must also remain in the groove in the shift lever housing.
4.38 Installing the lever guide
39. Install shift lever assembly with lever guide into larger hole in tool T10083 (see resist. illustration).
4.39 Tool T10083
Note: If necessary, first remove the lever so that its housing with guide can be inserted into the fixture.
The lever guide must protrude completely up from the shift lever housing.
40. Paste the end (And in illustration 4.37) springs in the guide from above. Pull the edge (IN) springs down and insert it next to the rail (in the direction of the swivel). Carefully remove the lever assembly from tool T10083.
41. Move the groove selection lever all the way back, in the direction of the arrow (1 per resist. illustrations). Lubricate the pivot pin with G000 450 02 and press it into the slot selector lever in the direction of the arrow (2). Don't damage the guides (A) and paws (IN).
4.41 Installing the pivot pin
42. Reinstall the shift lever assembly with lever guide into the larger hole in tool T10083 (see illustration 4.39). The lever guide must protrude completely up from the shift lever housing.
43. Lift the top edge (And on the opposite illustrations) springs above the finger of the slot selector lever. Lubricate the new pivot socket (IN) and guide hinge. Press the hinge socket into the hinge until it stops. Remove the lever assembly from tool T10083 and fix the hinge socket in the shift lever housing in four places (arrows). Insert bottom edge (WITH) springs into the guide, lift the top edge (A) springs above the finger of the groove selection lever into the guide.
4.43 Installing the spring
44. Connect Cables and Install Lever Assembly (see subsection above).
Checking and adjusting cables
45. In the neutral position, the lever should be in the groove between the 3rd and 4th gears. If there are persistent difficulties when selecting gears with the clutch pedal depressed, adjust the cables as described below.
46. Before adjustment, make sure that the moving parts of the working elements and the elements that transmit force are in good condition. The selector mechanism must move freely. Manual transmission, clutch and clutch drive must also be in good condition.
47. Engage neutral position.
48. Remove the air cleaner (see chapter 4).
49. Pull the bushings of the ends of the cables to the stop in the direction of the arrows (1 per resist. illustrations) and turn left in the direction of the arrows (2), to block.
4.49 Unlocking the cables
50. Lock the selector shaft. To do this, push it in the direction of the arrow (1 per resist. illustrations), while simultaneously turning the angle rod (A) up (arrow 3) and pressing it in the direction of the arrow (2).
4.50 Locking the selector shaft
51. Remove the gear lever boot (see relevant subsection above) and soundproofing (in the presence of). Lock the lever in the neutral position by inserting tool T10027A through the hole (And on the opposite illustrations) into the hole (B).
4.51 Locking the lever
52. Turn the locking mechanisms of the ends of the cables in the direction against the arrows (2 in illustration 4.49) to the stop, - the springs will press the locking mechanisms in the direction against the arrows (1) to the starting position.
53. Move the angle rod to its original position against the arrows (2 and 3 in Illustration 4.50), - the selector shaft must move.
54. Remove tool T10027A from the lever and check the adjustment (see paragraph 45).
55. Install the lever parts and air cleaner.