Removal
Intermediate crankcase installation details
37 - Helical gear 5th gear; 38 - Speedometer drive helical gear; 38a, 51 - Thrust washer; 42, 50 - Sealing gasket; 43, 43d, 45 - Outer bearing ring; 43a - Ball bearing; 43b, 54, 57 - Retaining rings; 43c - Roller bushing; 44 - Gaskets; 46 - Reverse gear shaft; 47, 80 - Bolt; 48 - Helical gear of the reverse gear; 49 - Intermediate crankcase; 52, 53 - Synchronizer ring; 55 - Needle bearing; 56 - Synchronizer clutch; 62 - Lid; 70 - Bearing pin; 71 - Spring; 72 - Bushing; 73 - Spring gasket; 74 - Nut; 75, 79 - Shift lever; 76 - Inner shift lever; 77 - Sealing ring; 78 - Lid; A - Gearbox with helical roller bearings (from 1 to 6141000); B - Gearbox with ball bearings (from 6141001)
1. Remove the gearbox (see section Removal and installation the gearbox).
2. Remove the rear cover of the gearbox (see section Removal and installation the rear cover of the gearbox).
3. Remove the speedometer gear (38) and thrust washer (38a).
4. Remove the retaining ring (57), synchronizer sleeve (56), synchronizer ring (38), synchronizer ring (52), needle bearing (55) and thrust washer (51).
5. Disconnect the helical gear (37) of the fifth gear.
6. Loosen the bolt (47) securing the reverse gear shaft (46).
7. On gearboxes with helical roller bearings, remove the intermediate case (49).
8. On gearboxes with ball bearings, disconnect the intermediate case (48).
Disassembly
1. Remove the 5th and reverse gear shift lever (79), cover (78) and sealing ring (77). Replace the sealing ring (77).
2. Remove the bearing pin (70), spring (71), bushing (72), spring gasket (73) and lever (75).
3. Press out the reverse gear shaft (46) and the reverse gear helical gear (48) from the intermediate housing.
4. On gearboxes with helical roller bearings, use a drift to press out the outer bearing rings (43) and (45).
5. Remove the roller sleeve (43c) and press out the outer bearing ring (43d) (on gearboxes with ball bearings).
6. Remove the outer bearing ring (43b) and press out the ball bearing (43a).
7. Measure the distance "a" between the contact surface and the groove of the bearing ring of the driven shaft of the gearbox on the old and new intermediate housings using a caliper (approximately 300 mm long). If the measurement result taken on the new intermediate crankcase does not correspond to the measurement result taken on the old one, it is necessary to install additional gaskets - gaskets with a thickness of 0.1, 0.3 and 0.5 mm are available.
8. Using the installation tool, press in the outer bearing ring.
9. On gearboxes with helical roller bearings, check the preload of the tapered roller bearings on the drive and intermediate shafts.
Installation
Installation is carried out in the reverse order of removal.