Special tool
 | Pinion Oil Seal Remover 205-078 (15-048) |
 | Differential Bearing Ring Puller 205-176 (15-074) |
 | Assembly stand for engine/differential 205-329 (15-105A) |
 | Installation tool 308-045 (16-015) |
 | 5th gear puller from primary shaft 5th gear puller from primary shaft 308-082 (16-035) |
 | Support bracket for 303-435 303-435-06 (21-031B) |
General equipment: Assembly stand.
1.
CAUTION: Handle the dual synchronizer components with care.
General note
- When performing all operations, protective pads must be installed on the vice jaws.
- To avoid damaging the gearbox components, use a copper or plastic mallet.
2. Secure the gearbox to the assembly stand.
3. Remove the clutch slave cylinder.
- 1. Remove the bolts.
- 2. Remove the clutch slave cylinder.
4. Remove the vehicle speed sensor (VSS).
- 1. Remove the pin.
- 2. Remove the VSS sensor.
5. Remove the gear shift cable cover.
6. Remove the gear selector lever.
- 1. Remove the protective cover.
- 2. Remove the retaining ring.
7. Remove the shift and selector cable brackets. Remove the boot.
8. Remove the cover and gear selector lock mechanisms.
- 1. Lid
- 2. 5th gear selection locking mechanism
- 3. Gear selector shaft locking mechanism.
9. Remove the retaining ring and gear selector pin.
- 1. Remove the retaining ring from the 5th gear and discard it as no longer needed.
- 2. Remove the retaining ring from the 5th gear synchronizer assembly and discard it as no longer needed.
- 3. Remove the pin and discard it as no longer needed.
10. Remove the 5th gear synchronizer together with the gear selection fork.
11.
NOTE: Before disassembling, mark the installation position of the synchronizer.
Disassemble the 5th gear synchronizer.
- 1. Retaining ring
- 2. Stop bar
- 3. Synchronizer
- 4. Synchronizer ring
- 5. 5th gear pinion
12. Remove the 5th gear.
13.
CAUTION: Do not strike directly on the mating surface.
Remove the 5th gear housing.
- 1. Remove the bolts and carefully separate the 5th gear housing sections by lightly tapping them.
- 2. Clean the mating surface.
14.
CAUTION: Do not strike directly on the mating surface.
Remove the retaining rings.
- 1. Remove the seal and discard it as no longer needed.
- 2. Remove the secondary shaft retaining ring and discard it as no longer needed.
- 3. Remove the primary shaft retaining ring and discard it as no longer needed.
- 4. Remove the technological plug.
15. Remove both oil seals (left side shown).
- Using a special tool, remove the front axle oil seals.
- The reverse light switch should only be removed for sealing purposes.
16.
NOTE: Rotate the crankcase slightly to raise it (the transmission breather line is attached to the input shaft).
Separate the transmission housing sections.
- Remove the bolts and carefully separate the crankcase sections by lightly tapping them.
- Clean the mating surface.
17. Remove the upper retaining ring from the gear selector shaft guide sleeve.
- 1. Remove the upper retaining ring and discard it as no longer needed.
- 2. Lower the gear selector shaft guide sleeve downwards.
18. Remove the gear selector rod guide sleeve.
- 1. Remove the lower guide bushing retaining ring and discard it as no longer needed.
- 2. Remove the gear selector rod guide sleeve.
19.
NOTE: To facilitate disassembly, attach a rubber strap to the auxiliary shift shaft.
Remove the primary and secondary shafts together with the gear selection forks.
20. Remove the reverse intermediate gear, differential and permanent magnet.
- 1. Reverse intermediate gear
- 2. Differential
- 3. Permanent magnet
21. Remove the gear selector rod together with the locking bar.
- 1. Gear shift locking sleeve
- 2. 5th gear/reverse gear selection rod
22. Remove the secondary shaft roller bearing.
- 1. Remove the rollers from the separator.
- 2. Remove the separator.
- 3. Remove the axle shaft oil seal.
23.
CAUTION: The special tool must be used in the position shown. Otherwise, the plug will be pulled out of the crankcase.
Remove the secondary shaft bearing inner race. Remove the oil nozzle.
24.
NOTE: For the disk installation sequence, see item 25.
Remove the inner bearing race.
25. Sequence of installation of differential discs.
- 1. Inner bearing ring
- 2. Adjusting gasket
- 3. Disc washers
26.
NOTE: Install the special tool into the crankcase recess.
Remove the differential bearing inner race.
