Disassembly of a manual transmission

1. Clean the surface of the gearbox with kerosene and wipe it dry.

2. Remove the clutch release bearing together with the lever.



3. Unscrew and remove the reversing light switch.



4. Loosen the clutch housing bolts (indicated by arrows) and take it off.

5. Unscrew the bolts and remove the clutch release bearing guide bush with gasket from the front of the gearbox.



6. Unscrew the mounting bolts and remove the top cover with gasket. The arrow shows the location of the spring locks for holding the engaged gear.




7. Unscrew the bolts and remove the 5th gear lock plate from the rear crankcase.

8. Remove the retaining spring with the 5th gear fork lock from the rear crankcase.

9. Use a screwdriver to knock out the rear cover of the rear crankcase through the hole for the gear lever.



10. Engage reverse gear and shift the axle of the gear selector lever back. Place the axle on a block of wood, then remove the selector roller retaining pin and remove the connector from the rear end of the selector rod.

11. Unscrew the bolts and remove the rear crankcase.



12. Remove the cover from the rear crankcase and remove the speedometer drive gear.




13. Set the gears to the neutral position, then use a hex wrench to unscrew the mounting screws and remove the plug of the gear selector lever retainer on the side of the gearbox housing, then remove the spring and retainer.

14. Remove pin from selector lever hub and from selector lever shaft.



15. Remove the centering spring of the selector lever shaft and the 5th gear retainer. To do this, use a small screwdriver to knock out the plug and pin and move the lock from the axle of the gear selector lever.

16. Mark the relative positions of the parts of the shift mechanism, then remove the shaft from the rear of the gearbox, remove the shaft sleeve and lock plate, the first / second, third / fourth forks, the fifth gear fork and adapter sleeve.




17. Remove the retaining ring and pull the fifth gear timing unit out of the common casing, leaving it free on the output shaft. Slide the 5th driven gear off the 5th gear hub.



18. Engage two gears at the same time (to lock the gearbox) and unscrew the nut securing the 5th gear on the intermediate shaft.

19. Using a rod, press back the axle of the intermediate shaft gear assembly. It is necessary to maintain constant contact of the rod with the axis of the intermediate shaft gear unit in order to prevent the bearing needles from falling out.

20. Attach the tool to the front of the gearbox housing.



21. Remove the 5th gear from the countershaft using tool 16.033.


22. Reinsert the pinion shaft of the countershaft into its original place by pushing out the shaft of special tool 16.033 by hand.

23. Remove the retaining ring from the gear block bearing in the middle of the gearbox housing.

24. Remove bearing spacer.

25. Disable both previously engaged gears.

26. Unscrew the bolt holding the middle part of the gearbox housing by 6–7 mm and move the middle part of the crankcase.



27. Press the gear cluster bearing into the middle of the crankcase using two thin screwdrivers (1 and 2 - screwdrivers, 3 - bolt) and remove the bearing outer race.

28. Move the axle of the gear cluster back enough to allow the gear cluster to be removed from the crankcase.

29. Lay the countershaft gear assembly on the bottom of the front of the gearbox housing.



30. Remove the output shaft together with the middle part of the crankcase.



31. Remove input shaft.



32. Using a suitable puller (large diameter bushing, M8x60 bolt with nut) remove the reverse gear shaft.

33. Remove retaining ring and reverse gear lever shaft.



34. Remove the magnet from the bottom of the input shaft housing.