Removing the gearbox housing bearing
1. Remove the gearbox from the vehicle.
2. Place the gearbox on a dismantling stand.
3. Remove the fifth gear housing (see relevant section above).
4. Remove the synchronizer and gears of the fifth gear.
5. Remove the gearbox housing:
- Loosen the gearbox housing bolts.
- With a special nozzle (Bvi. 1934) remove reverse switch (1).
- If equipped, remove locking pin (2) reverse gear shaft.
- Engage third gear.
- Disconnect and remove the gearbox housing.
Note:
- A press must be used to extract and install the bearings.
- The procedure described below is valid for both bearings.
6. Remove retaining ring (1).
7. Remove the bearing inside the crankcase using a mandrel for pressing the crankcase bearings (Bvi. 1576) (2).
Installing the gearbox housing bearing
Note: Be sure to replace with new removed bearings, oil seals, O-rings, clutch thrust bearing guide, roll pins, bearing circlips, clutch release cylinder (if equipped), magnet.
1. Use a cleaning agent to clean the bearing mounting surfaces in the gearbox housing and the gearbox housing itself.
2. Place a new circlip in the crankcase.
3. Place the bearing on the press-in tool (Bvi. 1576).
4. Using a press, install the bearing into the gearbox housing until it touches the circlip.
5. Verify that the circlip is properly seated in the bearing housing.
6. 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.
7. Install gears and fifth gear synchronizer.
8. Install the fifth gear housing.
9. Remove the gearbox from the stand.
10. Install the gearbox on the car.