- install the reverse intermediate gear on the axle, without pushing it all the way to the place, so that it can be engaged with the corresponding gear on the secondary shaft;
- install the primary, secondary and intermediate shafts simultaneously;
- after installing the shafts and pressing them into the sockets until their bearings stop, measure the recession of the bearings relative to the surface of the crankcase, i.e. the distance between the mating surface of the crankcase (with installed gasket) and the bearing separator. Measure the height of the secondary shaft rear bearing cap shoulder. The difference between the two measurements gives the thickness of the adjusting shims that need to be installed;
- when installing the secondary shaft flange, lock its mounting nut with a special adhesive such as Loctite applied to the thread and a lock washer;
- install the gear selector rod lock; insert the retainer springs into the sockets; install the reverse gear rod and fork, install the locking ball and the locking ball; insert the rod and the fork for switching the 1st and 2nd gears, putting the locking ball and the locking ball in place; install the gear selector shaft, securing it with a long pin; install the rod and the shift fork of the III and IV gears, inserting the locking ball;
- install the gearbox housing. If necessary, heat it to facilitate pressing in the front intermediate shaft bearing;
- install the rear cover on the crankcase. To do this, screw in the two mounting bolts without tightening them, and insert the mounting 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 front bearing of the primary shaft into the socket of the gearbox housing using a mandrel of the required size. Then install the device 611 in order to ensure the correct position of the primary shaft and bearing and to prevent jamming of the locking ring of the 4th gear synchronizer. Fit the adjusting ring and the retaining ring tightly onto the bearing. Measure the recession of the bearing separator relative to the plane of the gearbox housing. Measure the height of the flange of the guide sleeve of the clutch release bearing. The difference in measurements determines the thickness of the adjusting rings to be installed;
- secure the clutch release bearing guide sleeve;
- pour oil into the gearbox housing.
Gearbox installation
The gearbox is installed in the reverse order of removal. Bleed the clutch hydraulic drive (see section "Clutch").