Check the condition of the roller bearing 23 and replace it if necessary.
Heat the intermediate housing in the ball bearing press-in area to approx. 80°C and mount the secondary and intermediate shafts at the same time.
Establish locks on both parties of a secondary shaft.
Press gear 2, 1st gear, synchronizer blocking ring 3, needle bearing 4, synchronizer sliding clutch 5, 1st gear and reverse fork with stem 6 onto the secondary shaft, put cam 7 on the fork stem and secure it with a pin.
Install the split thrust ring of the 1st gear gear into the undercut of the secondary shaft.
Press the reverse gear 8, the needle bearing 9 and the shoulder sleeve 10 onto the output shaft. Heat the sleeve to approximately 80°C to facilitate installation.
Slide 0.5 mm thick adjusting ring 11, support ring 12, spacer 13, ball bearing 14, thrust washer 15 and speedometer drive gear 16 onto the output shaft.°C.
Install shift forks II and III, IV and V gears. The shift fork of IV and V gears has the greatest length. Insert the gear selector rod, putting the locking nuts in place. Install the gear selector as follows. so that its cutouts are facing down.
Remove three plugs.
Install needle bearing 17, spacer 18, needle bearing 19 and twin gear 20 on the output shaft.
Screw two guide rods into the bearing support ring. The notch of the support ring must face down. Lock spacer «S» (see photo).
Heat the rear cover of the gearbox housing to a temperature of about 80°C in the ball bearing press-in area.
Lubricate the gasket of the intermediate case of the gearbox.
Install the intermediate housing with shafts on the rear cover.
Insert the retainer balls and locking balls of the 1st gear and reverse fork rod into the sockets (see picture).
Slide the intermediate housing to the stop on the guide rods and tighten the bolts of its fastening to the rear cover.
Tighten bolts of fastening of a basic ring of the back bearing of a secondary shaft and turn out directing cores.
Insert the shift fork rod of the 2nd and 3rd gears into the support spring as far as it will go. Replace the retainer balls and locking balls. Move the fork stem to the stop and lock the fork with the pin.
Before installing stem 2 (see photo) shifting forks of IV and V gears, put the leash 3 on the gear selection rod.
Insert the 4th and 5th shift fork rod into the support spring as far as it will go. Replace the retainer balls and locking balls. Push the stem in until it stops. Insert the pins into the holes of the shift fork of the IV and V gears and the leash of the gear selection rod.
Install the plugs, lubricating them with sealant.
Install the gearbox output shaft flange and tighten its fastening nut, having previously applied Loctite type glue to the threads «Frenbloc». Bend the tab of the lock washer into the flange cutout. Install the gearbox housing.
Adjust the position of the ball bearings of the input and intermediate shafts relative to the front cover of the gearbox housing. Measure the protrusion of the bearings relative to the plane of the gearbox housing (size «G» for input shaft rear bearing and size «H» for intermediate shaft front bearing, see photo).
Install the gasket on the front cover of the gearbox housing and measure the depth of the socket «J» (see photo) for input shaft bearing and «TO» for intermediate shaft bearing.
Size difference «J» And «G» determines the thickness of the adjusting ring mounted on the input shaft, and the difference in size «TO» And «H» - the thickness of the adjusting ring mounted on the intermediate shaft.
Screw in the reverse light switch and install the gear selector rod retainer.
Heat the inner race of the ball bearing to 80°C and press it onto the intermediate shaft.
Press the bearing onto the input shaft in the same way using tool 23.1.000.
Press the bearings in until they stop. Install thrust washers. Lubricate the selected adjusting pegs and replace the circlips.
Install the transmission case front cover. When installing the bolts for its fastening, consider their dimensions:
- bolts 1-3 (see photo): 8x30mm;
- bolts 4-7: 8x22 mm.
These bolts must be installed with sealant.