Removing the clutch housing bearing
1. Remove the gearbox.
2. Place the gearbox on the assembly 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.
6. Remove gearbox shafts.
7. Remove differential.
Output shaft bearing
8. Cut off the base of the plastic hollow tube located in the center of the bearing.
9. Remove the bearing from the clutch housing using a sliding chipper (1) 40 mm in diameter.
Input shaft bearing
10. Using 38mm tube (3) press and press the input shaft bearing out of the clutch housing.
Clutch housing bearing installation
Note: Be sure to replace oil seals, O-rings, clutch thrust bearing guide, gear circlips, roll pins, shift rod spring studs, clutch release cylinder with new ones after each removal (if equipped), magnet, retaining ring and differential nut.
1. Use a cleaning agent to clean the shafts, shaft contact surfaces, differential, gearbox housing and clutch housing.
Output shaft bearing
2. Install a new oil deflector.
3. Install the output shaft bearing flush with the surface of the clutch housing.
4. Core (4) flatten the output shaft bearing in the clutch housing.
Input shaft bearing
5. Using a press and a special mandrel (Bvi. 1601) (6) install the input shaft bearing in the clutch housing.
Sequel for everyone
6. Install differential.
7. Install the gearbox shafts.
8. 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-grained 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 s 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.
9. Install gears and fifth gear synchronizer.
10. Install the fifth gear housing.
11. Remove the gearbox from the assembly stand.
12. Install the gearbox on the car.