Four-speed gearbox housings
1 – clutch housing; 2 – gearbox housing; 3 – oil filler plug; 4 – Reversing light switch; 5, 7, 8 – gasket; 6 – back cover; 9 – magnet; 10 – oil seals; 11 – speedometer drive gear; 12 – speedometer drive gear guide; 13 – circular section gasket; 14 – pin
Gears and shafts of a four-speed gearbox
1 – reverse gear; 2 – primary shaft spring retaining ring; 3 – bearing retaining ring, 4 – larger primary shaft rolling bearing; 5 – primary shaft; 6 – smaller primary shaft rolling bearing; 7 – secondary shaft spring retaining ring; 8 – bearing retaining ring; 9 – secondary shaft bearing; 10 – 4th gear pinion; 11 – synchronizer ring; 12 – synchronizer spring; 13 – retaining ring; 14 – hub of synchronizer of 3rd and 4th gear; 15 – sliding ring of synchronizer of 3rd and 4th gear; 16 – 3rd gear pinion; 17 – retaining ring; 18 – thrust half rings; 19 – 2nd gear pinion; 20 – retaining ring; 21 – hub of synchronizer of 1st and 2nd gear; 22 – 1st and 2nd gear synchronizer sliding ring; 23 – 1st gear pinion; 24 – secondary shaft; 25 – secondary shaft bearing; 26 – oil deflector; 27 – spring retaining ring; 28 – satellite; 29 – satellite axis; 30 – axle gear; 31 – satellite cage; 32 – differential tapered roller bearing; 33 – speedometer drive gear; 34 – circular section gasket; 35 – locking pin; 36 – speedometer drive guide; 37 – speedometer drive gear; 38 – bolt; 39 – differential box; 40 – driven gear of the main transmission; 41 – special spring washers; 42 – differential seal ring
Internal gear shift mechanism
1 – fork axle; 2 – 1st and 2nd gear fork; 3 – 3rd and 4th gear fork; 4 – ring; 5 – bushing; 6 – spring; 7 – gear shift rod; 8 – locking disk; 9 – retainer; 10 – spring; 11 – locking pin; 12 – bushings; 13 – gear shift shaft; 14 – wings; 15 – sealing ring; 16 – case; 17 – bracket; 18 – axis; 19 – gear shift levers; 20 – retaining ring; 21 – reverse gear lever; 22 – axis; 23 – retaining ring; 24 – bolt; 25 – pin
1. Thoroughly clean the splined portion of the gearbox input shaft protruding into the clutch housing and lubricate with an even thin layer of molybdenum grease.
2. Install a new gasket on the clutch housing. A small amount of grease may be used to secure the gasket.
3. Install the gearbox by inserting the input shaft into the clutch driven disk hub.
4. Insert the lower gearbox mounting bolts and tighten them to a torque of 35–45 Nm.
5. Attach the rear transmission bracket to the body and tighten the bolt.
6. Attach the front gearbox bracket with 4 bolts and manually screw new self-locking nuts onto the support mounting bolts.
7. Insert the locking pin, spring and screw in the gear selector shaft lock, after coating the threads with SM 4G-4544-AB locking agent.
8. Remove the plugs from the gearbox and insert the drive shafts into place, rotating the drive shaft until its splines are fully engaged with the differential axle gear, and then press on the wheel until the shaft is locked.
9. Screw the left wishbone to the body, insert the ball joint into the steering knuckle and tighten to the required torque. Install the right wishbone in the same manner.
Caution! When installing the wishbones, do not turn the Torx bolt under any circumstances.
10. Install the washer between the gearbox housing and the stabilizer, install the stabilizer and tighten the bolt to 55 Nm.
11. Using a 3.5 mm pin, secure the gearshift lever by inserting it into the hole at the bottom of the gearshift mechanism box. Install, adjust if necessary, and tighten the gearshift rod with the clamping bolt. To set the same clearances, set the gearshift lever shaft to the fourth gear position and rotate it clockwise until it stops. In this position, tighten the clamping bolt and remove the pin.
12. Install the shift rod return spring.
13. Install the starter and connect the wires.
14. Connect the connector to the reverse light switch.
15. Install and screw on the clutch housing cover.
16. Lower the car.
17. Remove the engine lifting device (beam).
18. Insert the upper gearbox mounting bolts and tighten them to a torque of 35–45 Nm.
19. Connect the end of the clutch cable to the lever.
20. Insert the speedometer drive cable into the gearbox and tighten it with the union nut.
21. Unscrew the oil filler plug and fill the gearbox with SAE 80 engine oil up to the lower edge of the oil filler hole, while the car must be in a horizontal position.
22. Place the heater hose on the thermostat and secure with a clamp.
23. Insert the gearbox ventilation pipe into the hole in the side member.
24. Connect the ground wire to the battery.