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Tools

• Trolley jack n stands
• Preferably engine crane with rope and special bracket to support gearbox
• Chisel or flathead screwdriver & hammer
• Philips screwdriver
• ½” ratchet or breaker bar
• torque wrench
• 10, 12, 13, 14, 17, 32mm sockets and spanners
• needle pliers
• emery cloth or file to clean dowels

Parts

• split pins
• graphite powder or copper grease
• gearbox oil if old oil is dirty
• zip ties

1. loosen front wheel nuts
2. jack front up with trolley jack under the front wishbone rear mount and place chassis beam on axle stands
3. remove the ½” drain plug under the gearbox and drain gear oil into a clean pan (1/2” ratchet/breaker bar) (if oil is golden and clean it can be reused, if its dirty black then replace), refit plug once empty.
4. disconnect battery (10mm spanner)
5. remove battery tray (12mm socket)
6. loosen clutch cable end locknut (10mm spanner) and loosen the thumbscrew till the bracket is slack and can unhook the bracket off the clutch arm
7. push the clutch outer cable backwards and sideways off the cable support bracket
8. remove clutch cable support bracket (12mm socket)
9. unplug starter motor connections (12mm & 10mm socket)
10. remove starter motor (14mm socket & extension)
11. remove gearbox top breather pipe
12. unplug the neutral gear switch connector at top rear of gearbox
13. unplug reverse switch at end of gearbox
14. unplug grounding wire from gearbox casing at the back just above the LH driveshaft
15. unscrew speedo outer cable off the gearbox (22mm spanner or by hand)
16. unclip the engine loom from the rear engine mount bracket at back of gearbox (flathead screwdriver)
17. remove front wheels
18. remove the hub centre dust cap (with a chisel or flathead between the lip of cap and the hub)
19. remove driveshaft nut split pin (pliers)
20. apply brakes to lock hub (either wedge a pole between seat & brake pedal or ask a helper)
21. remove driveshaft nut (breaker bar & 32mm socket)
22. release brake pedal
23. unclip brake hose from strut support tab (flathead & hammer)
24. unbolt ABS cable from strut support tab if fitted (10mm socket)
25. remove front caliper (12mm spanner), ziptie to the strut
26. remove pads
27. remove brake carrier from hub (17mm spanner) (wipe dirt off the pad clips with brake/carb cleaner till its shiny smooth)
28. remove disc
29. unbolt hub from strut (17mm socket)
30. pull hub outwards and separate driveshaft off the hub (turn the steering when needed to allow hub to move out enough)
31. separate inner driveshaft from gearbox by levering a flathead on the groove feature of the inner CV (NOT the thin metal cover shield at the ends of the CV joint) against the gearbox casing (there’s a small notch groove at bottom of casing to stick the flathead through) to overcome the spring clip at end of the shaft. Then remove driveshaft
32. support the rear of the gearbox with trolley jack
33. place a block of wood between the sump and the lower middle support beam
34. disconnect gear selector rod from gearbox (12mm spanners)
35. remove rear mount through-bolt (14mm socket) and gear selector stabiliser rod
36. unbolt rear mount bracket from gearbox/engine (14mm socket & extension)
37. remove LH mount through-bolt (14mm socket)
38. remove LH mount from gearbox (14mm socket)
39. lower the jack so the block of wood is supporting the engine against the middle beam
40. support the weight of the gearbox:
    1. with a crane and levelling hook bracket (most relaxed & safest method for person & gearbox and easy to carefully position n slot gearbox into dowels) http://micra.org.uk/threads/pollymobiles-rebuild.35251/page-49#post-508870
    2. trolley jack underneath (risk of slipping off and damaging input shaft and tricky to align dowels during fitting)
    3. rolling dolly underneath (tricky to align dowels during fitting)
    4. back breaking labour (big risk of dropping and damaging input shaft and tricky to align dowels during fitting)
41. unbolt gearbox from engine (14mm socket & extension)
42. jiggle & separate gearbox off the engine block dowels, always keeping the input shaft aligned to the crankshaft till they separate
43. remove gearbox
44. replace thrust bearing (clean and apply fresh lube to the sliding surface with graphite powder or light smear of grease)
45. lock flywheel starter ring against engine block with a piece of metal
46. undo the pressure plate bolts half-turns in a star pattern (12mm socket)
47. check flywheel face. If deeply worn, tapered, scored or damaged then get it resurfaced (13mm socket)

1. clean flywheel face and new PP face with brake/carb cleaner
2. use clutch centre tool to hold the new clutch plate centre to the PP
3. bolt the PP assembly to the fly in star pattern then remove alignment tool
4. clean/sand the gearbox locating dowels so gearbox can slide in easy
5. optionally fit the gearbox/engine splash plate (I left mine off cos its not essential and makes gearbox fitting a PITA)
6. lift gearbox up into position
7. slot the input shaft into the clutch plate always keeping it aligned to the crank
8. rotate the gearbox till the dowels line up and jiggle it in so the dowels secure the gearboxes position
9. bolt the gearbox to the engine
10. fit LH mount
11. fit rear mount bracket
12. clip engine loom onto rear mount bracket
13. fit gear selector rods
14. fit drive shafts into gearbox (use a dab of grease to keep that end spring clip centred on the shaft)
15. fit drive shaft through hub
16. bolt hub to struts
17. fit discs
18. fit brake carrier to hub
19. fit pads
20. fit calliper
21. clip brake hose onto strut
22. attach ABS cable to strut
23. apply brakes to lock hub
24. tighten drive shaft nut to spec
25. release brakes
26. fit split pin
27. fit hub dust cap
28. fit wheels
29. connect gearbox reverse, neutral and grounding wires
30. fit and wire up starter motor
31. fit gearbox breather pipe
32. fit clutch cable support bracket
33. fit clutch cable onto support bracket
34. fit clutch cable end onto clutch arm
35. screw clutch cable thumbscrew all the way up
36. lower car onto floor
37. tighten wheel nuts
38. remove airbox to access the speedo hole
39. unbolt and remove the speedo unit off the gearbox (10mm socket)
40. stick pipe & funnel into the speedo hole and fill the gearbox with 3L oil (reuse good old clean oil or fresh oil) (can use the engine dipstick down the gearbox hole to check fill level)
41. fit speedo into gearbox
42. fit speedo cable to gearbox speedo
43. fit airbox
44. fit battery tray
45. fit battery
46. start engine and select a gear
47. check and adjust the clutch cable thumbscrew till the clutch bite point is half way
48. tighten the clutch cable thumbscrew locknut