Clamp the gearbox at the intermediate case level into the bracket and install the gearbox with the bracket on a rotating stand for disassembly.
Drain the oil from the gearbox housing.
Place the gearbox in a vertical position.
Remove the clutch release fork and the clutch release bearing from the guide sleeve of the front gearbox cover.
Remove the front gearbox cover.
Remove the retaining ring and adjusting rings from the front input shaft bearing.
Place the box in a horizontal position and unscrew the reverse light switch.
Unscrew the plug of the gear selector rod retainer, remove the spring and the locking cracker.
Move the two intermediate case dowel pins toward the rear transmission cover.
After straightening the lock washer, unscrew the nut from the rear end of the secondary shaft, blocking it from turning with lock 6039 and using a 30 mm long sleeve.
Install a protective sleeve on the end of the secondary shaft.
Press the flange off the secondary shaft using a puller.
Loosen the bolts securing the secondary shaft rear bearing cover
Warning: The right upper bolt of the secondary shaft rear bearing cover shown by the arrow in the photo is 3 mm shorter than the others.
Remove the secondary shaft rear bearing cap and adjusting rings.
Remove the bolts securing the rear cover to the intermediate gearbox housing, except for the left upper bolt
Place the gearbox with the clutch housing facing up.
Screw tool 23 1 020 onto the gearbox housing and use tool 33 1 301 to remove the gearbox housing.
Note the position of the front intermediate shaft bearing, which is installed with the large diameter of the separator away from the gear block.
Place the gearbox in a horizontal position and press the two mounting pins of the rear cover into the sockets.
Engage 2nd gear and unscrew the left upper bolt securing the rear cover to the intermediate gearbox housing.
Remove the rear gearbox cover using tool 33 1 301.
Note the position of the intermediate shaft rear bearing, which is installed with the large diameter of the separator away from the gear block. Remove the intermediate shaft rear bearing.
Turn off 2nd gear.
Using the Kukko 18.0 puller, remove the speedometer drive pinion with the spacer sleeve from the secondary shaft.
Knock out the pin from the end of the intermediate shaft and remove the tip and adjusting rings from the shaft.
Use the Kukko 23 1 050 puller to press the 5th gear off the intermediate shaft and press out the outer bearing ring.
Press the V gear with the synchronizer locking ring and needle bearing off the secondary shaft.
Remove the intermediate tie rod support, unscrew the hexagon socket head bolt on the top of the intermediate casing (an intermediate lever is installed on this bolt).
Remove the pin from the gear selector shaft.
Remove the intermediate rod, intermediate lever and gear selector rod, remove the four locking crackers.
Slightly move the 5th gear and reverse gear fork rod and remove the 5th gear and reverse gear synchronizer crackers.
Remove the pin from the 5th gear engagement fork and press the synchronizer sliding sleeve.
Turn the V gear fork rod 1/2 turn and remove it; at the same time, apply alignment marks to the fork.
Remove the retainer ball.
Press off the hub of the 5th gear and reverse synchronizer clutch using the Kukko 23 1 050 puller. Remove the sleeve from the hub.
Remove the reverse gear and needle bearing.
Using mandrels 23 1 060, press out the reverse gear bushing and remove the adjusting rings.
Remove the pin from the 1st and 2nd gear shift fork and move it towards the clutch housing.
Engage IV gear and remove the pin from the III and IV gear shift fork.
Remove the shift fork rods for I and II, III and IV gears.
Remove the four retainer balls from the intermediate housing.
Remove the shafts from the intermediate crankcase.