While holding the secondary shaft flange from turning with lock 23.1.150, unscrew the flange nut with socket wrench 23.1.210.
Press the flange off the secondary shaft using puller 33.1.150.
Engage third gear.
Knock out pins 2 and 3 (see photo) from the gear shift forks and pin 1 from the gear selector rod linkage.
Remove the rod 4 of the shift fork for IV and V gears.
Turn the leash 5 upward and remove it from the gear selection rod.
Remove the rod 6 of the 2nd and 3rd gear shift fork.
Warning: This will release the retainer balls.
Remove the five Allen head cap screws located around the transmission secondary shaft.
Disconnect the intermediate gearbox housing from the rear cover.
Heat the rear cover of the gearbox housing in the area where the ball bearings are installed.
Disconnect the intermediate gearbox housing from the rear cover together with the primary, secondary and intermediate shafts, and the gear selection rod.
Clamp the intermediate case in a vice, taking care not to damage the mating surfaces.
Pull the gear selector shaft back out, removing the locking crackers at the same time.
Remove the shift forks for II and III, IV and V gears.
Press the speedometer drive pinion, thrust washer, ball bearing, support ring and reverse gear off the secondary shaft using a Kukko double-lever puller or similar.
Save the adjusting rings.
Knock out pin 7 (see photo) from the 1st gear and reverse gear engagement fork.
Remove the split thrust ring from the 1st gear.
Remove the 1st gear and reverse gear shift fork rod from the secondary shaft together with the sliding sleeve, synchronizer locking ring, 1st gear pinion and needle bearing. At the same time, remove cam 9 (see photo) from the fork rod.
Remove the two Allen head cap screws located on either side of the secondary shaft and remove the locks.
Heat the intermediate housing in the ball bearing pressing area to approximately 80°C.
Press out or knock out the secondary and intermediate shafts at the same time.
Disassemble the gear block in the following order: input shaft, synchronizer ring, needle bearing, snap ring and thrust washer.
Press the sliding clutch and synchronizer locking ring, fourth gear pinion, and needle bearing off the primary shaft.
Press the sleeve with shoulder, bearing, 2nd gear, synchronizer sliding sleeve and 3rd gear from the secondary shaft.
Check the condition of the synchronizer.