Transmission — assembly

Differential

1. The differential assembly is similar to that described for 1.6 liter models.

Secondary shaft

2. Install the right inner bearing race.

3. Install the 1st gear and locking ring.

4. Correctly oriented (pic. 6.31), install the 1st/2nd gear synchronizer.



5. Place the bushing on the hub (Pic. 6.32). Then the 2nd gear locking ring.



6. Install the thrust ring for fastening the synchronizer. They are available in different thicknesses 1.95 mm - 2.10 mm in 0.05 mm increments. Select the thrust ring so that the play is within the specified limits.


7. Install the 2nd gear, then 3rd, 4th and 5th.

8. Install the thrust ring for securing the 5th gear. They are also available in different thicknesses to adjust the play between the thrust ring and the groove.

9. After selecting and installing the correct thickness thrust washer, install the thrust washer.

10. Install the left inner bearing race.

11. Measure the lateral play of the 1st and 2nd gears again, check that it is within the specified limits.

Input shaft

12. Place the right inner race of the bearing.

13. Install the 3rd gear and locking ring.

14. Correctly oriented (pic. 6.33), install the 3/4 gear synchronizer hub.



15. Using heavy grease, secure the three inserts into the grooves of the synchronizer bushing (pic. 6.34), install the bushing into the hub, then the 4th gear locking ring.




16. Install the thrust ring for securing the synchronizer. They are available in different thicknesses, in 0.05 mm increments from 1.95 mm to 2.10 mm. Select the desired thickness of the thrust ring based on the measured play.

17. Install the 4th gear.

18. The 4th gear thrust washers also have different thicknesses, in 0.025 mm increments from 4.500 mm to 4.575 mm. Select a pair of washers so that the play between the thrust washers and the groove is within the specified limits.

19. Install the thrust washer retaining ring (Pic. 6.35).



20. Install the 5th gear and locking ring.

21. Install the 5th gear synchronizer hub.

22. Use heavy grease to secure the three insert springs in the grooves of the synchronizer bushing (pic. 6.36), install the bushing on the hub.




23. Install the left bearing. See point 2 above, but ensure that pressure is only applied to the inner race of the bearing.

24. Measure the side play of the 3rd, 4th and 5th gears again.

Transmission housing

25. If the differential side bearings or output shaft bearing have been replaced, the bearing preload will need to be adjusted. Install the outer rings.

26. Don't forget to install the oil chute.

Clutch housing

27. Install the oil seal.

28. Install the output shaft and differential side bearing outer rings.

29. Don't forget to install the oil pocket and magnet.

General assembly

30. Position the lever in the clutch housing, insert the rod. Secure the rod in the lever with a pin (Pic. 6.37). Install the drain plug.



31. Turn on the selector with the lever, insert the selector shaft, securing it with a pin.

32. Place the reverse lock assembly and tighten the bolts to the tightening torque specified in the Specifications.

33. Install the differential assembly.

34. Install the suspension to the 1st/2nd gear bias fork rod, secure them with a pin. Install the 1st/2nd gear bias fork to the rod and secure them with a pin. Place the fork on the 1st/2nd gear synchronizer clutch.


35. Place the input and output shaft assemblies together and install them into the clutch housing, being careful not to damage the input shaft seal.

36. Insert the locking ball, plunger, and ball for fixing the 1st/2nd gear fork rod (Pic. 6.38).





37. Position the 3rd/4th gear bias fork on the 3rd/4th gear synchronizer clutch of the input shaft.

38. Position the suspension, insert the 3rd/4th gear fork link. Align the holes and insert the mounting pin. Place the new stopper under the bias fork.

39. Insert the plunger and two locking balls of the 3rd/4th gear fork.

40. Position the 5th gear bias fork on the 5th gear synchronizer clutch of the input shaft.

41. Position the pendant. insert the 5th gear fork link. Align the holes and insert the mounting pin. Install a new stopper.

42. Insert the 5th/3rd gear ball retainer and the spring, tighten the retainer plug with the tightening torque specified in the Specifications.

43. Place the reverse lever assembly and the steel ball, tighten the bolts with the tightening torque specified in the Specifications.

44. Insert the reverse shaft, install the pin.

45. Engage 4th gear. Place the reverse idler gear, then insert the shaft, position the end of the shaft assembly as shown in Fig. 6.40.





46. Lubricate the left input shaft bearing spacers and place them in the housing.

47. Before installing the transmission housing, place the selector either to the 1st/2nd gear fork link hanger or between the 3rd/4th and 1st/2nd gear hangers.

48. Apply sealant to the mating surfaces of the transmission housing and clutch housing.

49. Lower the gearbox housing onto the clutch housing, tighten the bolts to the tightening torque specified in Specifications.

50. Insert the 1st/2nd and 3rd/4th gear ball retainers and springs. Tighten the plugs to the tightening torque specified in Specifications.

51. Install the reverse countershaft bolt, apply sealant to the threads of the reverse gear countershaft bolt, and tighten it to the torque specified in Specifications.

52. Install the gear selector switch.

53. Check various adjustments (see Chapter 15), measuring the overall torque of the transmission. Continue as described in Chapter 10, item 63, note that pop tool number K.V38106500 is now required.

54. Install the clutch release mechanism parts as described in Section 5.

55. Rotating the input shaft. check that all gears engage with relative ease.