Note: Be sure to replace oil seals, O-rings, clutch thrust bearing guide, gear circlips, roll pins, bearing circlips, shift rod spring studs, clutch release cylinder with new ones after each removal (if equipped), magnet.
1. Use a cleaning agent to clean the shafts, shaft mounting surfaces and gearbox housing
Versions with closed differential
2. Install differential (17).
3. Install the secondary shaft with the first-second switching before * 1 (18).
4. Install input shaft (19).
5. Install reverse gear assembly (20).
6. Install retard pins (21).
7. Install fifth gear stem
8. Install the fork and the shift rod of the third-fourth gear assembly (23).
9. Turn the rear code shaft so that the fifth gear fork is inserted into the recess (24).
10. Insert the pin into the reverse gear shaft (25).
11. Engage third gear.
12.Insert springs (26) and rollers (27).
13. Install the fourth gear (28) with synchronizer.
14. Install the washer and output shaft bearing.
Versions with open differential
15. Simultaneously insert the primary (29) and secondary (30) shafts with a fork and a shift rod of the first-second gears (31).
16. Install retard pins (32).
17. Raise the primary and secondary shafts and install the third-fourth shift fork.
18. Install the cylindrical pin in the shift fork of the third-fourth gear using a special tool (Bvi. 949) (33).
19. Lifting the input shaft, install the reverse gear shaft (34).
Sequel for everyone
20.Check for the presence of dowel pins (35) and magnet (36).
21. Install washers.
22.Install the gearbox housing:
- Clean the contact surfaces of the gearbox housing with a strong cleaning agent.
- Remove sealant residues from the contact surfaces with a plastic spatula.
- Sand the contact surfaces with fine sandpaper.
Attention:
- The sealing surfaces must be clean, dry and free from grease to ensure the required tightness (avoid any fingerprints).
- Excess applied sealant may be squeezed out when tightening threaded connections. Sealant entering the coolant may cause damage to some components (engine, radiator, etc.).
- Insert the 1st-2nd, 3rd-4th and 5th gear ball detent cartridges into the gearbox housing.
- Install detent springs and balls not fitted with cartridges.
- Fix the balls with a special tool (Bvi. 1570) (3).
- Make sure third gear is engaged.
- Check for dowel pins (4) and magnet (5).
- Apply a bead of rubber sealant to the contact surfaces of the gearbox housing.
- Install the gearbox housing by pointing the shift pin (6) into the third gear (7).
- Insert the fixing ball of the fifth gear rod, not equipped with a cartridge.
- If equipped, insert locking pin (8) reverse gear shaft.
- Install the gearbox housing bolts.
- Rotate the input shaft to make sure the bearings are seated correctly.
- Tighten gearbox housing bolts to 25 Nm.
- With nozzle (Bvi. 1934) install the reverse switch and tighten to 25 Nm.
23.Install fifth gears with synchronizer.
24.Install the fifth gear housing
25. Remove gearbox from assembly stand.
26. Install the gearbox on the car.