Removal

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





NOTE:
^ Before the gearbox is dismantled:
^ the oil in the gearbox should be drained
^ the reversing light switch should be removed to prevent it from being damaged. Cover the hole for the switch.
^ the speedometer drive should be removed by removing the screw.
^ After the outside of the gearbox has been cleaned, work should commence as follows:





1. Place the gearbox in a stand with holder tool No. 87 92 228, or equivalent.
- Cover the holes for the differential.





2. Remove the inner actuator shaft by first removing the four securing screws.
- Remove the actuator shaft with adapter tool No. 87 90 917 and slide hammer tool No. 83 90 270, or equivalent.





3. Unscrew and remove the end cover and gasket.





4. Engage third gear to lock the gearbox and to prevent the latch balls of the gear changing mechanism from coming out.
- Tap out the latch pin for fifth gear selector fork.
- Remove fork and sleeve, install sleeve.

NOTE: To facilitate reinstalling: mark with a marking pen the sleeve's position in relation to the fifth gear's synchromesh hub before removing the sleeve.





5. Press down the sleeve to engage fifth gear.
- Two gears must be engaged simultaneously when the nut on the output shaft is unscrewed.
- Note that the sleeve can only be placed in the synchromesh hub when the high heels on the sleeve are opposite the deeper tooth gaps on the synchromesh hub.
6. Using a drift, knock out the lock on the nut on the output shaft. Remove the nut.

NOTE: In all work with dismantling of the gearbox a new nut and a new clamping sleeve should be installed during assembly, because the clamping sleeve has lost its spring action.





7. Remove the locking ring for the fifth gear's synchromesh hub.
- Lift out the fifth gear's synchromesh hub with its sleeve and pinion.
- It might be necessary to use puller tool No. 87 92 343, or equivalent.





8. Remove the screw for the reverse gear's shaft support in the gear case.
9. Unscrew and remove the screws in the parting surface between gear case/clutch case. Tap down the two guide sleeves.





10. Screw on two hook eye tools No. 87 92 129, or equivalent.
- Install tool protection sleeve tool No. 87 91 410, or equivalent, on output stub axle.
- Hook puller tool No. 87 91 287 with puller arms tool No. 87 91 303, or equivalent, on to the hook eye tools and pull the case out carefully.
- First check that third or fourth gear is engaged.
11. Press out the gear case with its gears and bearings.
- Remove the tools.





12. Remove the fork shaft and the gear selector fork for reverse gear.





13. Unscrew and remove the reverse gear lever.

NOTE:
^ The two screws are not standard length (45 mm).
^ One is 20 mm long and the other is 50 mm long.





14. Engage reverse gear on the gear change mechanism to gain access to the screw for the gear selector shaft.
15. Remove the screw for the carrier on the gear selector shaft.
- Pull out the shaft and put the carrier in a safe place.





16. Disengage reverse and engage fourth gear on the gear change mechanism.
- Remove the screw and lift up the gear change mechanism slightly, so that the guide sleeves come out of their positions.
- Remove the sleeves.
- Pull the gear change mechanism backwards towards the differential and swing it out slightly.
- Lift out the gear change mechanism.





17. Slightly lift the input shaft and lift up the reverse gear shaft with its pinion (the reverse gear).





18. Place puller with puller arms tool No. 87 91 295, or equivalent, under the first gear's wheels on the output shaft.
- Place protection sleeve as a protection on the output stub axle.
- Tighten slightly and install tool output shaft assembly tool No. 87 92 103, or equivalent, which holds first and second gears' synchromesh mechanism together.
- Install a tie strap around tool and unit.
- Pull all the gear wheels about 15 mm up on the output shaft.
19. Lift out the output shaft.
20. Continue to pull until the gear wheels on the output shaft come loose.





21. First lift off the fourth gear wheels, clamping sleeve, spacing sleeve and third gear wheels.
- Then lift out the rest of the gear wheels (first and second), baulk rings and sleeve, which are held together by an output shaft assembly tool and secured by a tie strap.





22. Remove the four screws and remove the output shaft's bearing support.





23. Pull up the output shaft.
- Use tools support tube tool No. 87 91 188, support ring tool No. 87 91 972 and screw press tool No. 87 91 261, or equivalents.





24. Lift out the differential by setting the notch in the differential against the bulge by the output shaft's bearing support.