915 Assembly

- Place the same number and thickness of shims on the transmission housing studs as noted during disassembly or as determined while adjusting the pinion.
- Insert 1st and 2nd speed selector fork rod.
- Insert 1st and 2nd speed shift detent and spring.
^ Torque retaining bolt to: 17 Nm (12.5 ft lb)




- Insert pinion shaft with 1st and 2nd speed selector fork so that the pinion comes barely to rest in the bearing race of the transmission housing.

NOTE: To keep the selector fork from binding on the selector fork rod. slightly open the selector fork clamping piece with a screwdriver.

- Insert input shaft and push into place together with the pinion shaft.
^ Torque clamping plate nuts to: 24 Nm (17.7 ft lbs)
- Lightly tighten selector fork bolt (1st and 2nd speed). Insert detent from the top.





- Unscrew bolts for 3rd and 4th speed selector fork and fork clamping piece. Push fork and clamping plate back so ha the selector fork and rod can be installed.
- Lightly tighten selector fork and fork piece bolts.
- Insert shift detent and spring.
^ Torque plug to: 17 Nm (12.5 ft lb)
- Adjust selector forks. Adjustments
- Place transmission housing gasket on the studs.
- Install gear housing together with selector fork rod (5th speed and reverse) and selector shaft.
^ Torque to: 24 Nm (17.7 ft lbs)
- Push selector fork rod in the ball sleeve. and selector shaft into the shift pawl guides.
- Install guide fork cover and gasket.
^ Torque to: 24 Nm (17.7 ft lbs)
- Install idler gear shaft turning the shaft until the pin in the gear housing prevents it from turning.
- Install reverse speed gear I and start castellated nut on threads.
- Install thrust washer for 5th speed free gear.
- Install needle bearing with 5th speed free gear.
- Install guide sleeve for 5th and reverse speed. start flange nut on threads.
- Install thrust needle bearing cage. idler gear with needle bearing cages and intermediate piece and thrust washer on the idler shaft.
- Slide 5th speed and reverse sliding gear with selector fork on guide sleeve and selector fork rod. Slightly open the selector fork clamping piece for easier assembly.
- Lightly tighten selector fork bolt.
- Apply light coat of oil to the 0-ring and install.





- Block input shaft with special tool P 37a, and engage 5th gear.
^ Torque input shaft castellated nut to: 160 Nm (118 ft lb)
^ Torque pinion shaft flange nut to: 250 Nm (184.3 ft lb)
- Adjust 5th and reverse speed selector fork.
- Secure castellated nut with roll pin; and flange nut by notching.
- Insert actuating pin for backup light switch with recessed end toward switch.
- Place gear housing gasket on studs. Install front transmission cover.
^Torque nuts to: 24 Nm (17.7 ft lbs)