Draining and refilling oil Pic. 3.34. Drain and filler holes for manual transmission JH3, JR5: 1 - drain plug; 2 - filler plug Oil used: TRANSELF TRJ 75 W80W. Pic. 3.35. Drain and filler holes of a manual transmission ND0: 1 - drain plug; 2 -...
Precautions during the work Repair the transmission in a clean room and in a clean work area. Thoroughly clean the gearbox before opening it. During breaks in work, carefully cover the open gearbox to prevent foreign particles from entering it....
Removal, replacement and installation of the differential seal (JH3, JR5) Removing Place the car on a two post lift. Disconnect the wires from the battery terminals, starting with the negative terminal. Remove the engine undertray. Drain the gearbox oil. Remove: wheel; mudguard; hub nut; tie...
Removal, replacement and installation of the differential seal (ND0) Removing Place the car on a two post lift. Disconnect the wires from the battery terminals, starting with the negative terminal. Remove the engine undertray. Drain the gearbox oil. Remove: right wheel; right mudguard;...
Removal and installation of a manual transmission To prevent breakage of the contact disc under the steering wheel, the following instructions must be observed: before disconnecting the steering shaft from the steering mechanism, be sure to block the steering wheel and...
Disassembly of a manual transmission Install mounting plate (B.Vi.1581) on the rack (Desvil). Pic. 3.55. Installing the gearbox on the mounting plate Install the gearbox on the mounting plate (B.Vi.1581) (pic. 3.55). Remove the clutch release cylinder....
Replacing bearings in the crankcase Pic. 3.70. Pushing the bearing into the crankcase Spread the circlips with appropriate pliers and press the bearing into the crankcase using the tool (B.Vi.1576) (pic. 3.70). Installation Pic. 3.71. New spring rings...
Removal and installation of gears The bushings under the gears of the 2nd, 3rd, 4th gears are installed with an interference fit. During assembly, they must be systematically replaced. Pic. 3.77. Assembly Removal «ring, hub and third gear» Using a...
Replacing input shaft bearings Pic. 3.81. Pressing out the bearing Press out the bearings with a puller (pic. 3.81). Pic. 3.82. Pressing in a bearing Press in the bearings using a 25 mm bushing (pic. 3.82). Pic. 3.83. Removing the input shaft bearing...
Replacing the bearing on the clutch housing side Cut off the plastic capsule located in the center of the bearing at the base. Pic. 3.86. Removing the bearing from the crankcase Install fixture (B.Vi.1165) and remove the bearing (pic. 3.86). Pic. 3.87. Installing the...
Adjustment of a preload of bearings of a secondary shaft Note. Adjust only when bearings are replaced Install output shaft into clutch housing with bearings and pre-adjustment ring (V.Vi.1161) or similar ring 1.60 mm thick (large outside diameter). Install crankcase. Wrap and...
Adjusting the axial clearance of the output shaft bearings Note. Adjust only when bearings are replaced. Install input shaft with bearings and pre-adjustment ring (V.Vi.1161) 0.62 mm thick (small outside diameter). Install differential housing, install and tighten box connector...
Removing the differential and replacing bearings (JH box) To remove the O-ring, tap on the O-ring using a thin barrel punch and a hammer. This is necessary to check it out. Pic. 3.93. Removing the sealing ring Remove the O-ring, taking care not to damage the splines of the...
Removing the differential and replacing bearings (JR box) To remove the O-ring, tap on the O-ring using a thin barrel punch and a hammer. This is necessary to check it out. Pic. 3.100. Removing the sealing ring Remove the O-ring, taking care not to damage the splines of the...
Replacement of bearing cages Pic. 3.106. Installation of bearing cages (large diameter) Push out the bearing cages with a bushing inserted inside the crankcase (pic. 3.106). Installation Pic. 3.106. Installation of bearing cages (large diameter)...
Control axis The control shaft is provided with a shut-off valve attached to crankcase A. The tightness is ensured by the O-ring B. Pic. 3.110. control axis (JR box) After removing the pins of the selector lever C, remove the...
Shaft installation Pic. 3.112. Installing input shaft and output shaft with 1/2 yoke Install input shaft and output shaft at the same time with 1/2 yoke (pic. 3.112). Pic. 3.113. 1/2 stem lock pin A and fifth gear stem lock pin B Install...