Driving and driven gears for manual transmission up to No. 0210417
Removing
Driving and driven gears of the gearbox up to No. 0210417
2 - Drive shaft; 20 - Driven shaft; 40 - Intermediate shaft; 101, 114, 119 - Bolts; 102, 103a, 110, 112 - Gaskets; 103 - Shaft; 106 - Finger; 107 - Locking lever; 108, 118 - Sleeve; 109 - Blocking leaf spring; 111 - Nut; 113 - Blocking bearing; 115 - O-ring; 116 - Cover; 117 - 3rd/4th gear lever; 120 - 1/2 gear lever
1. Remove block bearing (113).
2. Remove the shift lever (117) and shaft (103) 1/2 gear.
3. Remove the driven shaft (20) from the gearbox housing.
4. Remove the shift lever (120) and shaft (103) 3/4th gear.
5. Remove the lever with the fork and 3/4 gear shift clutch.
6. Remove intermediate shaft (40) from the gearbox housing.
7. Remove the drive shaft (2) with tapered roller bearing and 4th gear synchronizer ring.
8. Using a drift, knock out the outer races of the intermediate and input shaft bearings from the gearbox housing.
9. Loosen the nut (111), press out and remove the finger (106) with locking leaf spring (109), locking lever (107), sleeve (108) and gasket (110).
Installation
1. Install the lock lever (107), blocking leaf spring (109), sleeve (108) and gasket (110) on the finger (106). Press in the pin (106) through the gearbox housing from the inside and secure it with a new nut (111).
2. Install intermediate shaft (40) into the gearbox housing. 3. Fix the coupling (10) with fork (13) and lever (14) on the input shaft and synchronizer so that the groove in the clutch (10) was directed upward.
4. Insert the shaft (103) inclusion of 3/4th gears in the gearbox housing. Lubricate the bolt (101) sealant and screw it in.
5. Insert lever (117) engage 3/4th gear so that it engages with the splines of the gear lever. Insert sleeve (118), lubricate the bolt (119) sealant and tighten it.
6. Insert the drive shaft (20) into the gearbox housing. 7. Install the shaft (103) engaging 1/2 gears in the gearbox housing (101), lubricating it with sealant, and tighten the mounting bolt.
8. Install the engagement lever (117) 3/4th gear so that it engages with the gear lever splines. Insert sleeve (118), lubricate the bolt (119) sealant and tighten it.
9. Insert blocking bearing (113) into the gearbox housing so that one ball is installed downwards towards the nut.
10. Tighten block bearing (113) bolt (114).
Driving and driven gears of manual transmission from No. 0210418 to No. 6141000
Removing
Driving and driven gears of manual transmission from No. 0210418 to No. 6141000
2 - Drive shaft; 20 - Driven shaft; 40 - Intermediate shaft; 101, 114, 119 - Bolts; 102, 103a, 110, 112, 122, 123 - Gaskets; 106 - Finger; 107 - Locking lever; 108, 118 - Sleeve; 109 - Blocking leaf spring; 111 - Nut; 113 - Blocking bearing; 115 - O-ring; 116 - Cover; 117 - 3rd / 4th gear shift lever; 120 - 1st / 2nd gear shift lever; 121 - Spring; 124 - Thrust bearing; 125 - Needle bearing; 126 - Disc; 127 - Retaining ring; 128 - Ball bearing
1. Remove block bearing (113).
2. Remove the shift lever (117) and shaft (103) 1/2 gear.
3. Remove the driven shaft (20) from the gearbox housing.
4. Remove the shift lever (120) and shaft (103) 3/4th gear.
5. Remove intermediate shaft (40) from the gearbox housing.
6. Remove the drive shaft (2) with tapered roller bearing and 4th gear synchronizer ring.
7. Remove the needle bearing (125) and disk (126) from the drive shaft (2).
8. Remove the needle bearing (125), thrust bearing (124), gaskets (122), (123) and spring (121) from the drive shaft.
9. Remove the bearing outer race from the intermediate and drive shafts using a punch.
10. Loosen the nut (111), press out and remove the finger (106) with lock leaf spring (109), locking lever (107), sleeve (108) and gasket (110).
Installation
1. Install the lock lever (107), blocking leaf spring (109), sleeve (108) and gasket (110) on the finger (106). Press in the pin (106) through the gearbox housing from the inside and secure it with a new nut (111).
2. Using a drift, carefully tap in the bearing outer race until it protrudes about 2mm (for intermediate shaft) and 6 mm (for drive shaft).
3. Insert the drive shaft (2) with tapered roller bearing and synchronizer for engaging 4th gear in the gearbox housing.
4. Install intermediate shaft (40) into the gearbox housing 5. Fasten the clutch (10) with fork (13) and lever (14) on the input shaft and synchronizer so that the groove in the clutch (10) was directed upward.
6. Insert shaft (103) inclusion of 3/4th gears in the gearbox housing. Lubricate the bolt (101) sealant and screw it in.
7. Insert lever (117) engage 3/4th gear so that it engages with the splines of the gear lever. Insert sleeve (118), lubricate the bolt (119) sealant and tighten it.
8. Insert driven ox (20) into the gearbox housing.
9. Install the shaft (103) 1/2 gears into the gearbox housing, lubricating it with sealant, and tighten the fastening bolt (101).
10. Install the engagement lever (117) 3/4th gear so that it engages with the gear lever splines. Insert sleeve (118), lubricate the bolt (119) sealant and tighten it.
11. Insert blocking bearing (113) into the gearbox housing so that one ball is installed downwards towards the nut.
12. Tighten block bearing (113) bolts (114).
Driving and driven gears of manual transmission from No. 6141001
Removing
Driving and driven gears of manual transmission from No. 6141001
1a, 128 - Ball bearings; 1b, 127 - Retaining rings; 2 - Drive shaft; 20 - Driven shaft; 40 - Intermediate shaft; 101, 114, 119 - Bolts; 102, 103a, 110, 112, 122, 123 - Gaskets; 103 - Shaft; 106 - Finger; 107 - Locking lever; 108, 118 - Bushings; 109 - Blocking leaf spring; 111 - Nut; 113 - Blocking bearing; 115 - O-ring; 116 - Cover; 117 - 3rd / 4th gear shift lever; 120 - 1st / 2nd gear shift lever; 121 - Spring; 122a - Sleeve; 125 - Needle bearing; 127 - Retaining ring; 128 - Ball bearing
1. Remove block bearing (113).
2. Remove shift lever (117) and shaft (103) 1/2 gear.
3. Remove retaining ring (127) ball bearing (128) intermediate shaft (40).
4. Remove the front ball bearing (128) from intermediate shaft (40).
5. Remove the driven shaft (20) from the gearbox housing.
6. Remove shift lever (120) and shaft (103) 3/4th gear.
7. Remove the lever with the fork and the 3/4 shift clutch.
8. Remove intermediate shaft (40) from the gearbox housing.
9. Remove the drive shaft (2) from the gearbox housing.
10. Remove the needle bearing (125) and sleeve (122a) from the drive shaft (2).
11. Loosen the nut (111) and remove your finger (106) with locking leaf spring (109), locking lever (107), sleeve (108) and gasket (110).
Installation
1. Install the lock lever (107), blocking leaf spring (109), sleeve (108) and gasket (110) on the finger (106). Press in the pin (106) through the gearbox housing from the inside and secure it with a new nut (111).
2. Fix the needle bearing (125) and sleeve (122a) on the drive shaft (2). 3. Press onto the drive shaft (2) ball bearing (1a), install retaining ring (1b) and install the drive shaft (2) into the gearbox housing.
4. Install intermediate shaft (40) into the gearbox housing.
5. Fasten the coupler (10) with fork (13) and lever (14) on the input shaft and synchronizer so that the groove in the clutch (10) was directed upward.
6. Insert shaft (103) inclusion of 3/4th gears in the gearbox housing. Lubricate the bolt (101) sealant and screw it in.
7. Insert lever (117) engage 3/4th gear so that it engages with the splines of the gear lever. Insert sleeve (118), lubricate the bolt (119) sealant and tighten it.
8. Insert the drive shaft (20) into the gearbox housing.
9. Install the shaft (103) engaging 1/2 gears in the gearbox housing. Lubricate the bolt (101) sealant and screw it in.
10. Install the engagement lever (117) 3/4th gear so that it engages with the gear lever splines. Insert sleeve (118), lubricate the bolt (119) sealant and tighten it.
11. Screw press 124 589 0931 00 onto the intermediate housing and fix the intermediate shaft with bolts.
12. Press in the ball bearing (128) into the bearing seat on the intermediate shaft using press 124 589 00 15 00. Move back the bolts of the press 124 589 09 31 00 on the intermediate shaft by approx. 2 cm (128) into the gearbox housing.
13. Install retaining ring (127).
14. Insert blocking bearing (113) into the gearbox housing so that one ball is installed downwards towards the nut.
15. Tighten block bearing (113) bolts (114).