Installation

NOTE: Component identifier numbers used in the following illustrations relate to specific steps in the procedures below.





NOTE:
^ General measures before assembly.
^ Check the condition of the parts as regards wear.
^ Replace damaged or defective parts.
^ Before assembly, oil all bearings and friction surfaces with suitable 10W30 engine oil.
^ Fill the sealing ring for the input shaft between the sealing lips with Shell Grease 1344 LIEP II, or equivalent.
^ Sparingly grease the input shaft's plate-splines with Shell Retinax AM, or equivalent.

1. Place the clutch case in the assembly stand with fixture tool No, 87 92 228, or equivalent, and suitable spacing sleeves.
2. Scrape off old residues of sealant from the parting surface.
- Also clean any sealant residues from the gear case.





3. Place the differential in the clutch case.
- Note the notch in the differential against the bulge by the output shaft's bearing support.





4. Place the output shaft in its seat and install the bearing race with a plastic hammer.
- Insert the bearing support and tap down with a plastic hammer and installing ring tool No. 87 92 202 with sleeve tube tool No. 87 91 204, or equivalents.
- Install the screws and tighten the three screws in the middle alternately with a torque of 33-43 Nm (24-32 ft. lbs.).
- Note that the outermost screw should only be tightened with 20-28 Nm (15-21 ft. lbs.).





5. Install the first and second gears' gear wheels with their synchromesh unit (which have previously been assembled,) on the output shaft with assembly tool No. 87 92 103, or equivalent.
- Install the third gear's gear wheels and spacing sleeve on the output shaft.
- Do not let the installed gear wheels come too far down the shaft, leave 15 mm, otherwise it will not be possible to install the input shaft.
6. Place the input shaft in the case.
- Install a suitable tie strap to keep the teeth of the input and output shafts engaged.





7. Press down the gear wheels on the output shaft towards the surface of the clutch case.
- Tap with a plastic hammer using sleeve tube with assembly ring tool No. 87 90 867, or equivalents, until it is possible to insert ANOTHER CLAMPING SLEEVE and the fourth gear's gear wheel.
- Turn the fourth gear's gear wheel so that the machining marks face upwards.





8. Install tool screw press tool No. 87 91 261, or equivalent, and pull down until the fourth gear's pinion and gear wheels on the input and output shafts are level with each other.
- Cut off the tie strap and remove tool output shaft assembly tool.





9. Slightly lift the input shaft and install the reverse gear with its pinion and synchromesh.
- The hole in the reverse shaft should be facing the channel in the clutch case.





10. Install the gear change mechanism in the clutch case with the first gear's fork in first gear's position on the gear change mechanism and push up the sleeve towards the second gear's synchromesh position on the output shaft.
- Push up the sleeve in the fourth gear's synchromesh position on the input shaft.
11. Install first-second gears' and third-fourth gears' forks in their sleeves. Turn and push the mechanism into place.
- Disengage first gear by lifting up the fork with a screwdriver.
- Insert the guide sleeves and install one of the screws.





12. Install the reverse gear lever with the two remaining screws.

- Tighten the three screws (reverse gear lever and gear change mechanism share one screw) with a torque of 20-28 Nm (15-21 ft. lbs.).

NOTE:
^ The reverse gear lever's two screws are 20 and 50 mm long.
^ The longer 50 mm screw is shared by the reverse gear lever and the gear change mechanism.

CAUTION: The oil plate of the reverse gear lever should be installed under the edge of the gear change mechanism.





13. Install the fork on the reverse gear's sleeve.
- Ensure that the reverse gear lever enters the grooves of the reverse gear fork.
- Then push in the fork shaft.
- Engage reverse gear on the gear change mechanism.





14. Place gear selector shaft in position, sparingly lubricated with Mobile Grease 57C or Shell Grease 1344 LIEP II, or equivalent.

NOTE: Turn the gear selector shaft with the bevelled hole facing upwards.

15. Thread in and install the carrier in place, push in the gear selector shaft and install the screw.
- Tighten to a torque of 20-28 Nm (15-21 ft. lbs.).
16. Hold down each shaft and test by changing gear.
- Then engage third or fourth gear.

CAUTION: If a bearing on the output shaft or differential has been replaced, the seal holder must be removed and the differential bearing race pressed out of the gear case so that the differential preload can be measured later.





17. Sparingly apply Loctite 518, or equivalent to the contact surfaces of both the gear box case and the clutch case.
- Brush out the Loctite and allow it to dry for a couple of minutes.

CAUTION:
^ Be very careful when assembling the gearbox and applying Loctite.
^ If the sintered plug (by the arrow) in the gearbox ventilation is blocked, the oil in the gearbox could be forced out.





18. Ensure that the reverse shaft support is correctly placed, so that the screw can be installed after the gear case has been installed.
Place the gear case on the clutch case.

NOTE: Cover the holes in the gear case, so that nothing can enter the gearbox by mistake.





19. First secure the clutch case and the gear case lightly with two screws.
- Then tap up the guide sleeves.
- Install the screw for the reverse shaft; if necessary, push it with a narrow screwdriver to guide the screw to the hole in the gear case.
- Install remaining screws.
- Tightening torque: 20-28 Nm (15-21 ft. lbs.)





20. Install the bearing on the output shaft and pull it down with the screw press.
- Do not pull it all the way down to the bottom against the outer bearing race.





21. Install the fifth gear wheel on the output shaft.
- Tap down the fifth gear wheel, if necessary, with a plastic hammer and the sleeve tube so that the screw press can be installed.
- Use the screw press to pull down the gear wheel.
- Install a new nut.
22. Install the fifth gear's pinion with its needle bearing, synchromesh, synchromesh hub and sleeve on the input shaft.
- The stop heels of the baulk ring should be positioned over the holes in the hub.
- It might be necessary to tap down the hub on to the input shaft's splines joint using the sleeve tube and a plastic hammer.





23. Install dial indicator tool No. 87 92 194 with stand tool No. 87 90 727, or equivalents.
- Engage third gear and push down the fifth gear's sleeve to "lock" the gearbox.
- Tighten the nut and measure alternately with the dial indicator until there is an axial play of 0.15-0.20 mm on the output shaft.
- Use a short 8 mm screw in the sealing surface as a fixed point.
- Lift out the fifth gear's sleeve.

CAUTION:
^ Do not lift directly below the teeth, insert the screwdriver properly
^ Do not forget to remove the 8 mm screw.





24. Place the dial indicator's measuring end on the shaft shoulder.
- Disengage the gear and install the fifth gear's sleeve.
- Install the turning adapter tool No. 87 92 053 on the output shaft and "run" the gearbox with an electric drill so that the bearings "settle".
- Press and pull the drill and run about 20 revolutions, both pressing and pulling.
- Remove the tool.
- Record the reading of the axial play and then add the nominal value.
- Swing out the dial indicator.

- NOMINAL VALUE, OUTPUT SHAFT:
- Old case (over 50,000 km): 0.12 mm
- Old bearing (over 50,000 km): 0.12 mm
- Old case up to 50,000 km: 0.15 mm
- Old bearing, up to 50,000 km: 0.15 mm
- Old case, up to and over 50,000 km: 0.20 mm
- New bearing: 0.20 mm
- New case: 0.26 mm
- New bearing: 0.26 mm

- EXAMPLE:
- Measured value 0.23 mm + 0.20 mm (nominal value) = 0.43 mm.





25. Install the fifth gear's sleeve and engage fifth gear by pressing down the sleeve.
- Ensure that the high heels on the sleeve rest against the deep tooth gaps on the synchromesh hub.
- Engage third gear.





26. Install millimeter disc tool No. 87 92 061 on the output shaft's nut.
- Mark up one tooth on the gear wheel with a felt tip pen or similar.
- Set the millimeter disc tool's scale to the calculated value (measured + nominal, see example).





27. Tighten in 2-3 stages until the millimeter disc tool's zero reading (O) is opposite the marked tooth.
- Upset the nut collar in three places on the fifth gear wheel to lock the nut.
- Remove millimeter disc tool and sleeve.





28. Lift off the fifth gear's pinion, synchromesh, synchromesh hub and sleeve.
- It might be necessary to use a puller to remove the hub.





29. If a bearing on the output shaft has been replaced or if differential bearings have been replaced, the differential's preload must be checked and if necessary adjusted as follows. (If not, go to step 32.)
- Install the milled bearing race tool No. 87 92 137, or equivalent instead of the bearing race which was previously pressed out.
- Remove the bearing support's O-ring and the actuator's plunger and spring.
- Insert a packet of shims of about 1.2 mm together with the bearing support.





30. Place 10 kg weight tool No. 87 92 095 on the bearing support.
- Install the turning adapter tool on the output shaft.
- Use an electric drill to run the differential at least 20 revolutions.
- Measure the play with a feeler gauge in three (3) places between the bearing support and the gear case.
- Take the mean value of the three readings and adjust to a value of:
- Old case (50,000 km): 0.20 mm
- Old bearing (50,000 km): 0.20 mm
- Old case (50,000 km): 0.30 mm
- New bearing: 0.30 mm
- New case: 0.35 mm
- New bearing: 0.35 mm

NOTE:
^ Thicker shims = Increase the preload.
^ Thinner shims = Reduce the preload.
^ Shims for the differential are available in the following sizes: 0.10, 0.15, 0.30 and 0.50 mm

31. Remove the 10 kg weight), differential bearing support and the milled bearing race.

CAUTION:
^ Do not forget to remove the milled bearing race and replace it with the bearing race.
^ Risk of damage to the gearbox.





32. Insert the bearing race with a plastic hammer.
- Install and lubricate the O-ring on the bearing support.
- Install plunger and spring.
- Install the screws and pull down the bearing support and measure the packet of shims with the bearing support.
- Tighten alternately to 20-28 Nm (15-21 ft. lbs.)
- Remove turning adapter tool from the output shaft.





33. Install shaft driver tool 87 91 428, or equivalent, on the input shaft.
- Place the measurement tip of the dial indicator on the bearing of the input shaft.
- Install an electric drill to the tool and "run" the gearbox to "settle" the bearings.
- Press and pull the drill and run about 20 revolutions, pulling and pressing.
- Measure the axial play.
- The axial play should be 0.04-0.11 mm.
- Adjust with shims under the bearing support if necessary.
- Thinner shims = less play;
- Thicker shims = more play.
- Shims are available in the following sizes: 0.10, 0.15 and 0.30 mm.
34. When adjusting the axial play on the input shaft.
- Remove the four screws on the bearing support.
- Install the bearing support together with the correct packet of shims and tighten alternately to 33-43 Nm (24-32 ft. lbs.).
- Measure the play again.
- Remove the three tools.

CAUTION: If the play is too small, the gear case must be removed and the bearing race pressed out again.





35. Check that fourth gear is engaged.
- Install the fifth gear's pinion, baulk ring and synchromesh hub.
- The stop heels of the baulk ring should be placed opposite the holes in the hub.
- It might be necessary to tap down the hub with sleeve tube tool and a plastic hammer.





36. Install the fifth gear's fork on its sleeve.
- Install fork and sleeve.
- The sleeve should be installed with the high heels against the synchromesh hub's deep teeth gaps.
- Install a new locking ring.
37. Hammer in the clamping pin in the gear change shaft.





38. Remove the cover over the gear case's holes.
- Install a new gasket and the end cover.
- Tighten the screws to 20-28 Nm (15-21 ft. lbs.).
39. Test the gear change mechanism by engaging all gears one by one.





40. Install the oil drain plug and seal with thread sealing liquid.
- Tighten to: 45-55 Nm (33-41 ft. lbs.).
- Check that the magnet is in place in the plug.





41. Oil should not be poured in until after the drive shafts have been installed on the gearbox and the gearbox installed into the car.
- Amount of oil (dry) 1.9 liters.
42. Reconnect the reverse light switch with a new seal after the gearbox has been installed into the car.
- Tightening torque: 20-28 Nm (15-21 ft. lbs.)
43. Install the speedometer drive.