Gear: Service and Repair

5th Gear Replacement With Transmission Installed (Part 1 Of 4):

5th Gear Replacement With Transmission Installed (Part 2 Of 4):

5th Gear Replacement With Transmission Installed (Part 3 Of 4):

5th Gear Replacement With Transmission Installed (Part 4 Of 4):

Removal Notes
1. Remove engine guard and rear underside panel.
2. Drain transmission oil.
3. Remove crossbrace.
4. Disengage shift rod coupling from inner shift rod.
5. Support transmission on general-purpose transmission jack and unbolt transmission support from body.
6. Lower engine-transmission assembly only so far that the assembly will not rest on the stabilizer bar.





7. Determine installation position of reverse shift fork for reinstallation, measuring dimension "A" with depth gauge.

Installation Notes
1. Tighten hexagon head nuts of drive pinion and input shaft to specified torque and lock the nuts.
2. Adjust reverse shift fork to the dimension "A" determined during removal and check adjustment.





3. Adjust inner shift rod so that all gears can be selected freely without binding.
- To achieve this, undo hexagon-head bolts of clamping plate and turn eccentric bushing.
4. Screw a long 8 mm bolt into the inner shift rod and shift through all gears to check operation.
5. Place engine-transmission assembly onto general-purpose transmission jack and raise into installation position.
- Attach transmission support to body
- Tighten to: 46 Nm (34 ft lb).

NOTE:
- Check engine compartment rubber seal between body and engine paneling for correct seating.
- If required, unbolt transmission support from body once more, correct seal position and refit transmission support.

6. Fit shift rod coupling to inner shift rod.
- Tighten to: 18 Nm (13 ft lb), apply Loctite 270 to threads.
7. Fill transmission with oil, refer to Specifications.