Removal of manual transmission of Fiat Punto

1 Firmly apply the handbrake, then jack up the front of the car and support it securely on axle stands.
2 Remove both front wheels, then remove the left-hand wheel arch liner main and centre panels.
3 Remove the air cleaner assembly.
4 Remove the battery, battery tray and starter motor.
5 Disconnect the gearchange selector cable end fittings from the transmission of Fiat Punto (ever ball-studs). Undo the three bolts securing the selector cable support bracket to the transmission and move the bracket and cables to one side.
6 Unbolt the clutch slave cylinder from the top of the transmission then fit a cable-tie around it to prevent the piston from being ejected. Position the cylinder to one side.
7 Disconnect the wiring connector from the reversing light switch on the front of the transmission, then unscrew the nut and disconnect the transmission earth lead from the top of the unit.

DOHC (16-valve) engine models

8 Remove the exhaust manifold.
9 Undo the bolts securing the engine management ECU mounting bracket to the throttle body and move the ECU to one side.

All models of Fiat Punto

10 Undo the bolts and remove the support brace linking the transmission to the cylinder block.
11 Unbolt and remove the cover plate from the base of the transmission beilhousing
12 Disconnect the wiring from the vehicle speed sensor located on the top of the transmission differential housing.
13 Unscrew the nuts retaining the track rod ends on the swivel hubs and use a balljoint separator of Fiat Punto tool to disconnect them.
14 Unscrew the two bolts securing the right-hand swivel hub assembly to the front suspension strut, then move the hub assembly outwards.
15 Remove the retaining clip securing the right-hand driveshaft inner CV joint garter to the joint body. Pull the driveshaft and spider out of the joint body and move the driveshaft clear of the engine/transmission. Suitably cover the joint body and the driveshaft spider to prevent the escape of grease.
16 Undo the two bolts securing the left-hand brake caliper mounting bracket to the swivel hub. Slide the caliper and mounting bracket off the brake disc and suitably support it clear of the work area.
17 On models of Fiat Punto equipped with ABS, undo the retaining bolt securing the left-hand wheel speed sensor to the swivel hub. Withdraw the sensor from the swivel hub and position it clear of the work area.
18 Unscrew the two bolts securing the left-hand swivel hub assembly to the front suspension strut, and separate the hub assembly from the strut.
19 Slacken and remove the nut and clamp bolt then lift the left-hand swivel hub off the suspension lower arm balljoint.
20 Remove the retaining clip securing the left-hand driveshaft inner CV joint gaiter to the joint body. Pull the driveshaft and spider out of the joint body and remove the driveshaft and swivel hub assembly from the car.
Suitably cover the joint body and the driveshaft spider to prevent the escape of grease.
21 Working beneath the car of Fiat Punto, unscrew the bolts and nuts securing the rear engine mounting to the subframe and transmission, and withdraw the mounting.
22 Support the weight of the engine using a hoist attached to home-made brackets secured to suitable positions at the left-hand end of the engine.
23 Support the weight of the transmission on a trolley jack then unscrew the engine-to-transmission retaining bolts. Move aside all wiring and support brackets secured by the retaining bolts.
24 Unscrew the bolts securing the left-hand engine/transmission mounting to the body then unscrew the bolts from the transmission and remove the mounting.
25 Check that ail pipes, hoses and wiring are moved clear then carefully pull the transmission away from the engine. Lower the trolley jack and remove the transmission from under the car.
Warning: Support the transmission to ensure that it remains steady on the jack head. Keep the transmission level until the input shaft is fully withdrawn from the clutch friction plate.

Refitting the manual transmission of Fiat Punto

26 Refitting is a reversal of the removal procedure, bearing in mind the following points.
a) Apply a smear of high-melting-point grease to the clutch friction plate splines; take care to avoid contaminating the friction surfaces.
b) Tighten all bolts to the specified torque.
c) Use new clips to secure the driveshaft gaiters to their respective joint bodies.