E Gear LAMBORGHINI GALLARDO 2009 Manual PDF
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® Automobili Lamborghini S.p.A. 7 K H L Q I R U P D W L R Q D Q G S U R F H G X U H V S X E O L V K H G E H O R Z D U H V W U L F W O \ F R Q ¿ G H Q W L D O D Q G H [ F O X V L Y H O \ I R U W K H / D P E R U J K L Q L ' H D O H U 1 H W Z R U N D Q G $ X W K R U L ] H G 6 H U Y L F H 3 R L Q W V $ O O F R S \ U L J K W V D U H S U R S H U W \ R I $ X W R P R E L O L
/ D P E R U J K L Q L 6 S $ E D V H G R Q F R S \ U L J K W O D Z $ O O R I W K H 3 ' ) F K D S W H U V L Q W K H : ( % Z R U N V K R S P D Q X D O V G H V F U L E H G E H O R Z D U H E D V H G R Q L Q I R U P D W L R Q D Y D L O D E O H D W W K H W L P H R I S X E O L F D W L R Q 7 K H F R P S D Q \ U H V H U Y H V
W K H U L J K W W R P D N H X S G D W H V D Q G P R G L ¿ F D W L R Q V 7 K H I R O O R Z L Q J D U H S U R K L E L W H G U H S U L Q W L Q J U H S U R G X F W L R Q I R U Z D U G L Q J W R X Q D X W K R U L ] H G S H R S O H D Q G R U W K L U G S D U W L H V D Q G W U D Q V O D W L R Q L Q F O X G L Q J S D U W L D O Z L W K R X W
Z U L W W H Q D X W K R U L ] D W L R Q I U R P $ X W R P R E L O L / D P E R U J K L Q L 6 S $
General instructions
Prior to starting work on the dismantling or assembing of the Gearbox and Differential assy, bear in mind the following points: •When working on the gearbox assy observe high standards of cleanliness. All parts should be cleaned throughly
prior to assembly.
• The location where the work is to be carried out should be dust-free clean.
• 0 D N H V X U H W K D W D O O W K H Q H F H V V D U \ W R R O V D U H D Y D L O D E O H S D U W L F X O D U O \ W K R V H P H Q W L R Q H G L Q W K L V P D Q X D O 3 D U W V ¿ W W H G
incorrectly can cause serious damage, in the same way as metal chips or foreign bodies.
• During the differential assy overhaul, you are advised tu substitute the following with new parts: oil sealing rings,
gaskets, retaining rings and any parts damaged during dismantling.
• If breakage occurs inside the planetary gears side or differential, all lines, casing and should be cleaned thor-
oughl to prevent damage caused by residues left inside the system.
SHIMS
All adjustments shall be carried out after all adjustment shims have been selected measuring them one by one with a micrometer gauge and, then, summing up all values measured; do not trust incorrect measurement of pack as a
unit or sum of nominal value printed on each shim.
SEALS FOR REVOLVING SHAFTS
3 U R F H H G D V I R O O R Z V I R U S U R S H U ¿ W W L Q J R I R L O V H D O V • prior assembly, seals should be soared, for at least half an hour, in a bath with the same oil to be sealed;
• F O H D Q W K R U R X J K O \ V K D I W D Q G P D N H V X U H W K D W Z R U N L Q J V X U I D F H L V Q R W G D P D J H G S R V L W L R Q V H D O L Q J O L S D J D L Q V W W K H À X L G
to be sealed; in case of hydrodynamic lip lines should be oriented so as that, considering direction of revolving
V K D I W W K H \ O H D G À X L G L Q V L G H R I V H D O L Q J P H D Q V
• V P H D U V H D O L Q J O L S Z L W K D ¿ O P R I O X E U L F D Q W R L O L V E H W W H U W K D Q J U H D V H D Q G ¿ O O X S Z L W K J U H D V H W K H V S D F H E H W Z H H Q
sealing lip and dust shield lip, if using double sealing lip type seals;
• S U H V V V H D O L Q U H O H Y D Q W S R V L W L R Q R U X V H D S U R S H U ¿ W W H U Z L W K À D W F R Q W D F W V X U I D F H Q H Y H U X V H K D P P H U R U P D O O H W W R
mount seal;
• Z K H Q S U H V V ¿ W W L Q J V H D O P D N H V X U H W K D W L W E H F R U U H F W O \ G U L Y H Q L Q U H O H Y D Q W S R V L W L R Q L H V T X D U H Z L W K U H V S H F W W R L W V
S R V L W L R Q D V ¿ W W L Q J L V F R P S O H W H G P D N H V X U H L I U H T X L U H G W K D W V H D O L W V H O I E H L Q F R Q W D F W Z L W K U H O H Y D Q W V K R X O G H U
• to prevent damage of seal lip when inserting shaft, duly protect component during assembly.
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® Automobili Lamborghini S.p.A. 7 K H L Q I R U P D W L R Q D Q G S U R F H G X U H V S X E O L V K H G E H O R Z D U H V W U L F W O \ F R Q ¿ G H Q W L D O D Q G H [ F O X V L Y H O \ I R U W K H / D P E R U J K L Q L ' H D O H U 1 H W Z R U N D Q G $ X W K R U L ] H G 6 H U Y L F H 3 R L Q W V $ O O F R S \ U L J K W V D U H S U R S H U W \ R I $ X W R P R E L O L
/ D P E R U J K L Q L 6 S $ E D V H G R Q F R S \ U L J K W O D Z $ O O R I W K H 3 ' ) F K D S W H U V L Q W K H : ( % Z R U N V K R S P D Q X D O V G H V F U L E H G E H O R Z D U H E D V H G R Q L Q I R U P D W L R Q D Y D L O D E O H D W W K H W L P H R I S X E O L F D W L R Q 7 K H F R P S D Q \ U H V H U Y H V
W K H U L J K W W R P D N H X S G D W H V D Q G P R G L ¿ F D W L R Q V 7 K H I R O O R Z L Q J D U H S U R K L E L W H G U H S U L Q W L Q J U H S U R G X F W L R Q I R U Z D U G L Q J W R X Q D X W K R U L ] H G S H R S O H D Q G R U W K L U G S D U W L H V D Q G W U D Q V O D W L R Q L Q F O X G L Q J S D U W L D O Z L W K R X W
Z U L W W H Q D X W K R U L ] D W L R Q I U R P $ X W R P R E L O L / D P E R U J K L Q L 6 S $
' L V D V V H P E O L Q J W K H J H D U E R [ P D Q X D O J H D U E R [ 3 U H O L P L Q D U \ R S H U D W L R Q V• Raise the vehicle on the car lift .
• Drain the engine oil circuit .
• Disassemble the rear tires .
• Disassemble the rear wheel arches .
• ' L V D V V H P E O H W K H U H D U Y H K L F O H À R R U .
• Disassemble the engine hood .
• Remove the engine internal panels (Engine Bay) .
• Disassemble the rear lights .
• Disassemble the upper panel .
• Remove the rear bumper .
• Remove the stabiliser bar .
• 5 H P R Y H W K H D L U ¿ O W H U D V V H P E O \ .
• Remove the exhaust terminal .
• Remove the oil tank .
' L V D V V H P E O L Q J W K H J H D U E R [1. Loosen the clamps on both sides ( A-Fig.1) securing the rear hood opening pipe to the chassis.
2. Disconnect the cable connector ( B-Fig.2) originating from the gearshift selector (reverse gear).
3. Disconnect the cable connector ( C-Fig.2) originating from the starter.
4. Disconnect the speed sensor connector ( D-Fig.2).
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Fig.3
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® Automobili Lamborghini S.p.A. 7 K H L Q I R U P D W L R Q D Q G S U R F H G X U H V S X E O L V K H G E H O R Z D U H V W U L F W O \ F R Q ¿ G H Q W L D O D Q G H [ F O X V L Y H O \ I R U W K H / D P E R U J K L Q L ' H D O H U 1 H W Z R U N D Q G $ X W K R U L ] H G 6 H U Y L F H 3 R L Q W V $ O O F R S \ U L J K W V D U H S U R S H U W \ R I $ X W R P R E L O L
/ D P E R U J K L Q L 6 S $ E D V H G R Q F R S \ U L J K W O D Z $ O O R I W K H 3 ' ) F K D S W H U V L Q W K H : ( % Z R U N V K R S P D Q X D O V G H V F U L E H G E H O R Z D U H E D V H G R Q L Q I R U P D W L R Q D Y D L O D E O H D W W K H W L P H R I S X E O L F D W L R Q 7 K H F R P S D Q \ U H V H U Y H V
W K H U L J K W W R P D N H X S G D W H V D Q G P R G L ¿ F D W L R Q V 7 K H I R O O R Z L Q J D U H S U R K L E L W H G U H S U L Q W L Q J U H S U R G X F W L R Q I R U Z D U G L Q J W R X Q D X W K R U L ] H G S H R S O H D Q G R U W K L U G S D U W L H V D Q G W U D Q V O D W L R Q L Q F O X G L Q J S D U W L D O Z L W K R X W
Z U L W W H Q D X W K R U L ] D W L R Q I U R P $ X W R P R E L O L / D P E R U J K L Q L 6 S $
Loosen the nut ( ( ) L J ) on both sides securing the gearbox to the chassis.
Loosen the screw ( F-Fig.3) securing the mounting bracket of the gearbox oil circuit pipes.
7. Disconnect the oil circuit delivery and return pipes ( G-Fig.3) from the gearbox.
& O R V H W K H J H D U E R [ K \ G U D X O L F F R Q Q H F W L R Q V X V L Q J W K H V S H F L ¿ F S O X J V W R S U H Y H Q W G L U W I U R P H Q W H U L Q J
3 R V L W L R Q D V X L W D E O H F R Q W D L Q H U W R F R O O H F W D Q \ U X Q R I I J H D U E R [ R L O
Disconnect the positive cable connector ( H-Fig.4) from the starter.
Disconnect the earth cable ( I-Fig.4) from the starter.
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/ D P E R U J K L Q L 6 S $ E D V H G R Q F R S \ U L J K W O D Z $ O O R I W K H 3 ' ) F K D S W H U V L Q W K H : ( % Z R U N V K R S P D Q X D O V G H V F U L E H G E H O R Z D U H E D V H G R Q L Q I R U P D W L R Q D Y D L O D E O H D W W K H W L P H R I S X E O L F D W L R Q 7 K H F R P S D Q \ U H V H U Y H V
W K H U L J K W W R P D N H X S G D W H V D Q G P R G L ¿ F D W L R Q V 7 K H I R O O R Z L Q J D U H S U R K L E L W H G U H S U L Q W L Q J U H S U R G X F W L R Q I R U Z D U G L Q J W R X Q D X W K R U L ] H G S H R S O H D Q G R U W K L U G S D U W L H V D Q G W U D Q V O D W L R Q L Q F O X G L Q J S D U W L D O Z L W K R X W
Z U L W W H Q D X W K R U L ] D W L R Q I U R P $ X W R P R E L O L / D P E R U J K L Q L 6 S $
10.Cut three clamps ( - ) L J ).
11. Loosen three screws ( . ) L J ) on the left side and remove the joint bulkhead ( / ) L J ) between the axle shaft
and the differential to release the gearbox.
12. Loosen the rear differential gearbox assembly support screw ( 0 ) L J ) and remove the bracket ( 1 ) L J ).
13. Loosen three screws ( 2 ) L J ) on the right side and remove the joint bulkhead ( 3 ) L J ) between the axle shaft
and the differential.
14. Loosen the rear differential gearbox assembly support screw ( 4 ) L J ) and remove the bracket ( 5 ) L J ).
Disconnect the two gear selection cables ( S-Fig.7).
Loosen three screws to remove the gear selection cable support bracket ( T-Fig.7).
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Fig.11
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Fig.12
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Fig.13
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® Automobili Lamborghini S.p.A. 7 K H L Q I R U P D W L R Q D Q G S U R F H G X U H V S X E O L V K H G E H O R Z D U H V W U L F W O \ F R Q ¿ G H Q W L D O D Q G H [ F O X V L Y H O \ I R U W K H / D P E R U J K L Q L ' H D O H U 1 H W Z R U N D Q G $ X W K R U L ] H G 6 H U Y L F H 3 R L Q W V $ O O F R S \ U L J K W V D U H S U R S H U W \ R I $ X W R P R E L O L
/ D P E R U J K L Q L 6 S $ E D V H G R Q F R S \ U L J K W O D Z $ O O R I W K H 3 ' ) F K D S W H U V L Q W K H : ( % Z R U N V K R S P D Q X D O V G H V F U L E H G E H O R Z D U H E D V H G R Q L Q I R U P D W L R Q D Y D L O D E O H D W W K H W L P H R I S X E O L F D W L R Q 7 K H F R P S D Q \ U H V H U Y H V
W K H U L J K W W R P D N H X S G D W H V D Q G P R G L ¿ F D W L R Q V 7 K H I R O O R Z L Q J D U H S U R K L E L W H G U H S U L Q W L Q J U H S U R G X F W L R Q I R U Z D U G L Q J W R X Q D X W K R U L ] H G S H R S O H D Q G R U W K L U G S D U W L H V D Q G W U D Q V O D W L R Q L Q F O X G L Q J S D U W L D O Z L W K R X W
Z U L W W H Q D X W K R U L ] D W L R Q I U R P $ X W R P R E L O L / D P E R U J K L Q L 6 S $
20.Loosen the four screws ( X-Fig.11) securing the engine to the chassis.
21. Loosen the nine screws ( Y-Fig.12) securing the gearbox housing to the engine.
22. Lift the engine slightly and remove the gearbox rear differential assembly ( Z-Fig.13) using a suitable lifting
device.
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Fig.1
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/ D P E R U J K L Q L 6 S $ E D V H G R Q F R S \ U L J K W O D Z $ O O R I W K H 3 ' ) F K D S W H U V L Q W K H : ( % Z R U N V K R S P D Q X D O V G H V F U L E H G E H O R Z D U H E D V H G R Q L Q I R U P D W L R Q D Y D L O D E O H D W W K H W L P H R I S X E O L F D W L R Q 7 K H F R P S D Q \ U H V H U Y H V
W K H U L J K W W R P D N H X S G D W H V D Q G P R G L ¿ F D W L R Q V 7 K H I R O O R Z L Q J D U H S U R K L E L W H G U H S U L Q W L Q J U H S U R G X F W L R Q I R U Z D U G L Q J W R X Q D X W K R U L ] H G S H R S O H D Q G R U W K L U G S D U W L H V D Q G W U D Q V O D W L R Q L Q F O X G L Q J S D U W L D O Z L W K R X W
Z U L W W H Q D X W K R U L ] D W L R Q I U R P $ X W R P R E L O L / D P E R U J K L Q L 6 S $
$ V V H P E O L Q J W K H J H D U E R [ P D Q X D O J H D U E R [ 1. Lift the engine ( A-Fig.1 V O L J K W O \ X V L Q J D V S H F L ¿ F O L I W L Q J G H Y L F H W R I D F L O L W D W H W K H F R Q Q H F W L R Q E H W Z H H Q W K H H Q J L Q H
D Q G W K H J H D U E R [ U H D U G L I I H U H Q W L D O D V V H P E O \
2. 3 R V L W L R Q W K H J H D U E R [ U H D U G L I I H U H Q W L D O D V V H P E O \ R Q W K H H Q J L Q H B-Fig.2
Important!
( Q V X U H W K H J H D U V K D I W (a -Fig.2 ) D Q G 3 7 2 V K D I W (b -Fig.2 ) D U H D O L J Q H G Z L W K W K H L U U H V S H F W L Y H H Q J L Q H
connections.
Lubricate the gear shaft (a -Fig.2 ) D Q G 3 7 2 V K D I W (b -Fig.2 ) junctures.
3. 7 L J K W H Q D V F U H Z C-Fig.2 W R V H F X U H W K H J H D U E R [ U H D U G L I I H U H Q W L D O D V V H P E O \ W R W K H H Q J L Q H
6 F U H Z D W W D F K P H Q W W L J K W H Q L Q J W R U T X H G 4. 7 L J K W H Q W K H U H P D L Q L Q J H L J K W V F U H Z V D-Fig.2 V H F X U L Q J W K H J H D U E R [ K R X V L Q J W R W K H H Q J L Q H
6 F U H Z D W W D F K P H Q W W L J K W H Q L Q J W R U T X H G
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W K H U L J K W W R P D N H X S G D W H V D Q G P R G L ¿ F D W L R Q V 7 K H I R O O R Z L Q J D U H S U R K L E L W H G U H S U L Q W L Q J U H S U R G X F W L R Q I R U Z D U G L Q J W R X Q D X W K R U L ] H G S H R S O H D Q G R U W K L U G S D U W L H V D Q G W U D Q V O D W L R Q L Q F O X G L Q J S D U W L D O Z L W K R X W
Z U L W W H Q D X W K R U L ] D W L R Q I U R P $ X W R P R E L O L / D P E R U J K L Q L 6 S $
$ ' L V D V V H P E O L Q J W K H J H D U E R [ R L O U D G L D W R U 3 U H O L P L Q D U \ R S H U D W L R Q V •Raise the vehicle on the car lift (000000).
• Disassemble the right rear wheel (060103).
• Disassemble the rear wheel arch (082103).
' L V D V V H P E O L Q J W K H U D G L D W R U 1. Loosen the 4 screws ( $ ) L J ) securing the two radiator mounting brackets ( % ) L J ) to the chassis.
1 R W H
Position a suitable container to collect the gearbox oil.
2. After releasing the radiator, disconnect the two gearbox oil circuit pipes ( & ) L J ).
3 . Remove the radiator including the air conveyors ( ' ) L J ).
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/ D P E R U J K L Q L 6 S $ E D V H G R Q F R S \ U L J K W O D Z $ O O R I W K H 3 ' ) F K D S W H U V L Q W K H : ( % Z R U N V K R S P D Q X D O V G H V F U L E H G E H O R Z D U H E D V H G R Q L Q I R U P D W L R Q D Y D L O D E O H D W W K H W L P H R I S X E O L F D W L R Q 7 K H F R P S D Q \ U H V H U Y H V
W K H U L J K W W R P D N H X S G D W H V D Q G P R G L ¿ F D W L R Q V 7 K H I R O O R Z L Q J D U H S U R K L E L W H G U H S U L Q W L Q J U H S U R G X F W L R Q I R U Z D U G L Q J W R X Q D X W K R U L ] H G S H R S O H D Q G R U W K L U G S D U W L H V D Q G W U D Q V O D W L R Q L Q F O X G L Q J S D U W L D O Z L W K R X W
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4. / R R V H Q W K H V S H F L ¿ F V F U H Z V * ) L J ) to remove the front conveyor ( ( ) L J ) and the rear conveyor ( )
) L J ).
5. Remove the gearbox oil radiator ( + ) L J ).
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® Automobili Lamborghini S.p.A. 7 K H L Q I R U P D W L R Q D Q G S U R F H G X U H V S X E O L V K H G E H O R Z D U H V W U L F W O \ F R Q ¿ G H Q W L D O D Q G H [ F O X V L Y H O \ I R U W K H / D P E R U J K L Q L ' H D O H U 1 H W Z R U N D Q G $ X W K R U L ] H G 6 H U Y L F H 3 R L Q W V $ O O F R S \ U L J K W V D U H S U R S H U W \ R I $ X W R P R E L O L
/ D P E R U J K L Q L 6 S $ E D V H G R Q F R S \ U L J K W O D Z $ O O R I W K H 3 ' ) F K D S W H U V L Q W K H : ( % Z R U N V K R S P D Q X D O V G H V F U L E H G E H O R Z D U H E D V H G R Q L Q I R U P D W L R Q D Y D L O D E O H D W W K H W L P H R I S X E O L F D W L R Q 7 K H F R P S D Q \ U H V H U Y H V
W K H U L J K W W R P D N H X S G D W H V D Q G P R G L ¿ F D W L R Q V 7 K H I R O O R Z L Q J D U H S U R K L E L W H G U H S U L Q W L Q J U H S U R G X F W L R Q I R U Z D U G L Q J W R X Q D X W K R U L ] H G S H R S O H D Q G R U W K L U G S D U W L H V D Q G W U D Q V O D W L R Q L Q F O X G L Q J S D U W L D O Z L W K R X W
Z U L W W H Q D X W K R U L ] D W L R Q I U R P $ X W R P R E L O L / D P E R U J K L Q L 6 S $
% ' L V D V V H P E O L Q J W K H J H D U E R [ R L O F L U F X L W S L S H V
The gearbox oil circuit is grouped as follows ( ) L J ):
A1. Front delivery pipe
A2. Front return pipe
3 Rear delivery pipe
3 Rear return pipe
Page 642 of 1659
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L714 03 17 03
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A1
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A1
® Automobili Lamborghini S.p.A.
7 K H L Q I R U P D W L R Q D Q G S U R F H G X U H V S X E O L V K H G E H O R Z D U H V W U L F W O \ F R Q ¿ G H Q W L D O D Q G H [ F O X V L Y H O \ I R U W K H / D P E R U J K L Q L ' H D O H U 1 H W Z R U N D Q G $ X W K R U L ] H G 6 H U Y L F H 3 R L Q W V $ O O F R S \ U L J K W V D U H S U R S H U W \ R I $ X W R P R E L O L
/ D P E R U J K L Q L 6 S $ E D V H G R Q F R S \ U L J K W O D Z $ O O R I W K H 3 ' ) F K D S W H U V L Q W K H : ( % Z R U N V K R S P D Q X D O V G H V F U L E H G E H O R Z D U H E D V H G R Q L Q I R U P D W L R Q D Y D L O D E O H D W W K H W L P H R I S X E O L F D W L R Q 7 K H F R P S D Q \ U H V H U Y H V
W K H U L J K W W R P D N H X S G D W H V D Q G P R G L ¿ F D W L R Q V 7 K H I R O O R Z L Q J D U H S U R K L E L W H G U H S U L Q W L Q J U H S U R G X F W L R Q I R U Z D U G L Q J W R X Q D X W K R U L ] H G S H R S O H D Q G R U W K L U G S D U W L H V D Q G W U D Q V O D W L R Q L Q F O X G L Q J S D U W L D O Z L W K R X W
Z U L W W H Q D X W K R U L ] D W L R Q I U R P $ X W R P R E L O L / D P E R U J K L Q L 6 S $
' , 6 $ 6 6 ( 0 % / , 1 * 7 + ( ) 5 2 1 7 3 , 3 ( 6 3 U H O L P L Q D U \ R S H U D W L R Q V •
Raise the vehicle on the car lift (000000).
• Disassemble the right rear wheel (060103).
• Disassemble the rear wheel arch (082103).
' L V D V V H P E O L Q J W K H $ D Q G $ J H D U E R [ R L O F L U F X L W S L S H V 1. Unscrew the nuts ( $ ) L J ) and disconnect the front A1and A2pipes from the gearbox oil radiator.
1 R W H
Position a suitable container to collect the gearbox oil.
2. Loosen the screw ( % ) L J ) fastening the gearbox oil radiator mounting bracket ( & ) L J ) to the chassis.