- install the intermediate reverse gear on the axle, without sending it completely to the place so that you can engage it with the corresponding gear of the output shaft;
- simultaneously put in place the primary, secondary and intermediate shafts;
- after installing the shafts and pressing them into the sockets until the stop of their bearings, measure the sinking of the bearings relative to the surface of the crankcase, i.e. distance between crankcase mating surface (with gasket installed) and bearing cage. Measure the height of the shoulder with the rear output shaft bearing cap. The difference between the two measurements gives the thickness of the shims to be installed;
- when installing the output shaft flange, lock the nut of its fastening with a special adhesive such as Loctite applied to the threads and a lock washer;
- install the gear selector rod lock; insert the retainer springs into the sockets; install the stem and fork of the reverse gear, put the retainer ball and the locking ball; insert the rod and the shift fork of I and II gears, putting the retainer ball and the locking ball in place; install the gear selection rod, securing it with a long pin; install the stem and shift fork of III and IV gears by inserting the locking ball;
- install the gearbox housing. If necessary, heat it to facilitate pressing the intermediate shaft front bearing;
- install the back cover on the crankcase. To do this, screw the two mounting bolts without tightening them, and insert the dowel pins into the sockets, then tighten the mounting bolts crosswise to the required torque;
- After installing the rear cover of the gearbox housing, press the input shaft front bearing into the seat of the gearbox housing using a mandrel of the desired size. After that, install tool 611 to ensure the correct position of the input shaft and bearing and to prevent jamming of the blocking ring of the 4th gear synchronizer. Fit the adjusting ring and circlip tightly onto the bearing. Measure the sinking of the bearing separator relative to the plane of the gearbox housing. Measure the height of the shoulder of the guide sleeve of the clutch release bearing. The difference in measurements determines the thickness of the installed adjusting rings;
- fix the guide sleeve of the clutch release bearing;
- pour oil into the gearbox housing.
Installing the gearbox
The gearbox is installed in the reverse order of removal. Bleed the hydraulic clutch (see section «Clutch»).