Front view of the clutch housing
1 – nut fixing plate, 2 – intermediate shaft bearing nut
Removal the clutch release bearing guide sleeve
1 – special device Ford 16.040
View of the left side of the gearbox
1 – Reverse gear stopper bolt, 2 – Selector gear stopper plug, 3 – Reverse gear light switch, 4 – Front reverse gear intermediate gear axle mounting bolt, 5 – Rear reverse gear intermediate gear axle mounting bolt
Removal the secondary shaft flange using a puller
Attention! After disassembling the gearbox, all spring retaining rings must be replaced with new ones of a thickness that ensures the required values of axial clearance of the elements installed with their help. All sealing rings must also be replaced.
The gearbox components (shafts, bearings, synchronizers, gear shift mechanism, etc.) are housed in two interconnected housings. The first of these, located closer to the engine, also contains the clutch and is called the clutch housing (although its rear section contains six gearbox components); the other is called the gearbox housing (although it does not contain all the elements of this unit).
1. Drain the oil from the gearbox.
2. Remove the release bearing and clutch release forks from the clutch housing.
3. Fix the flange of the front joint of the cardan shaft and unscrew the flange fastening nut by lightly tapping the key (1 - flange locking device, 2 - joint flange).
4. Using the Ford 16.040 tool, remove the clutch release bearing guide sleeve.
5. Remove the inner snap ring from the input shaft.
6. Remove the intermediate shaft bearing nut retaining plate (see Fig. Front view of the clutch housing).
7. Using a 17 mm wrench, unscrew the intermediate shaft bearing nut.
8. On the side of the crankcase, unscrew the bolts (Torx type) of the reverse gear stop (see Fig. View of the left side of the gearbox).
9. On the side of the crankcase, unscrew the plug (2) of the selector stopper and remove the spring, pusher, bushing and ball of the selector stopper.
10. Unscrew the switch (3) of the reverse lights.
11. Unscrew the two bolts (4 and 5) securing the reverse gear intermediate gear shaft and remove only the front bolt (4).
12. Unscrew the ten bolts connecting the clutch housing to the gearbox housing.
13. Using two screwdrivers, carefully separate the two halves of the gearbox housing.
14. Remove the clutch housing from the gearbox housing; if necessary, use device 16.041.
15. Remove the fork axle (1) (see Fig. Gear shift mechanism, gearbox type MT 75) 3-4 gears, 5th gear and reverse gear.
16. Remove the rear bolt (5) (see Fig. View of the left side of the gearbox) securing the reverse gear intermediate gear shaft.
17. Remove the magnet from the gearbox housing.
18. Using a suitable puller, remove the flange connecting the front joint of the cardan shaft from the secondary shaft (see Fig. Removing the secondary shaft flange using a puller).
19. Remove the sealing ring from the secondary shaft.
20. Remove the speedometer drive gear and spacer sleeve.
21. Pull the secondary shaft out of the gearbox housing using a puller.