Pic. 6.18. Selector mechanism - models 1.8 (including Turbo) and 2.0 liters
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Pic. 6.19. Transmission Internals - 1.8 Liter Models (including Turbo) and 2.0 liter models
1. With the transmission removed from the vehicle, clean dirt with water or kerosene and a stiff brush.
2. Remove the clutch release mechanism components from the clutch housing.
3. With the transmission installed on the surface of the clutch housing, first remove the gear position switch. See Chapter 5 of this Section.
4. Based on Fig. 6.21, unscrew the reverse gear intermediate shaft bolt, the 3rd/4th gear lock plug and the 1st/2nd gear lock plug. Remove the retainer springs and ball; labeling them and storing them separately with the corresponding plugs. Some models may have a dual 3rd/4th gear detent spring installed.
Pic. 6.21. Unscrewing the reverse intermediate shaft bolt (marked with an arrow), clamp plugs and position switch bolt
5. Unscrew the bolts and lift the transmission housing. Remove the left input shaft bearing spacers and lubrication channel.
6. If necessary, push the position switch out of the transmission housing.
7. With 4th gear selected, extend the reverse gear countershaft and remove the reverse gear from the reverse lever assembly.
8. Pull out the fastening button, use a hammer and a drift to knock out the plug from the reverse lever shaft (pic. 6.22). Throw away the O-ring and get a new one.
Pic. 6.22. Knock out the fastening pin of the reverse shaft lever and remove the shaft
9. Unscrew and remove the reverse lever assembly and steel ball retainer.
10. Unscrew the 5th/3X gear lock plug, remove the spring and ball (Pic. 6.23).
Pic. 6.23. Removing the 5/3X gear lock plug
11. Remove the snap rings from the 5th and 3rd/4th gear bias forks.
12. Push out the roll pins securing the fork hangers to the 5th/3X and 3rd/4th gear fork rods (Pic. 6.24).
Pic. 6.24. Removing the fork rods for 5th/3rd gear and 3/4th gears - the cylindrical pins are marked with arrows
13. Pull out the rods of the 5th/3rd gear and 3/4th gear forks, remove the bias and suspension forks.
14. Grab the primary and secondary shaft assemblies and lift them out of the clutch housing, along with the bias fork and 1st/2nd gear linkage (Pic. 6.25). Also lift up the differential assembly.
Pic. 6.25. Removing the input and output shaft with 1/2 gear fork, rod and hanger
15. Remove the balls and plungers from the clutch housing.
16. Unscrew the reverse lock assembly (Pic. 6.26).
Pic. 6.26. Removing the reverse lock assembly
17. Push out the selection shaft mounting pin, push out the shaft (Pic. 6.27 and 6.28) and remove the selector.
Pic. 6.27. Removing the drive roller fastening button
Pic. 6.28. Knocking out the leash roller
18. Unscrew the drain plug, push out the lever mounting pin (Pic. 6.29).
Pic. 6.29. Removing the lever fastening button
Pic. 6.30. Measuring side play - input shaft 3rd and 4th gears shown
19. Remove the rod and lever.
Clutch housing
20. Replace the input shaft, differential and linkage seals as described previously.
21. Refer to Chapter 8 of this Section for details on removing and installing the output shaft and/or differential bearing outer races.
22. Remove and clean the oil pocket and magnet.
Transmission housing
23. Remove and install the differential seal.
24. Remove and install the bias yoke shaft bushing.
25. Remove and install the bias fork shaft bushing as described in Chapters 8 and 9.
26. Remove and clean the oil chute.
27. Don’t break traffic jams unless absolutely necessary. If necessary, they can be removed as described in Chapter 8 and install new ones as described in Chapter 9.
Input shaft
28. Using a feeler gauge, measure the play of the 3rd, 4th and 5th gears. Record the resulting values.
29. Several parts are pressed on the input (and day off) Vale. It is preferable to have a bearing puller (see photos 8.27 and 8.36) to remove such parts. If a puller is not available, the component must be carefully clamped in a large vice and the shaft must be driven out with a soft mallet.
30. Pull off the left bearing.
31. Then pull off the 5th gear and synchronizer.
32. Remove the retaining ring and thrust washer, then the 4th gear.
33. Remove the thrust ring.
34. Pull off the 3rd gear and 3rd/4th gear synchronizer.
35. Remove the right bearing, if necessary.
Output shaft
36. Using a feeler gauge, measure the backlash of the 1st and 2nd gears, write down the results.
37. Press out the inner race of the left bearing.
38. Remove the thrust washer, remove the thrust ring.
39. Press out the 4th and 5th gears.
40. Similarly, press the 2nd and 3rd gears together.
41. Remove the thrust ring.
42. Pull together the 1st gear and synchronizer (which includes the reverse gear) 1st/2nd gear.
43. Tighten the right bearing inner race if necessary.
Differential
44. Remove the differential as described earlier (on these models there is no speedometer drive gear stopper).