Removing
1. Turn away the lever of inclusion of 2/3rd transfers.
2. Unscrew the shaft (103) 2/3rd gear and remove the shift lever from the gearbox (120).
3. Unhook the spring (109), remove the intermediate shaft (110) and remove the driven shaft (140) from the gearbox.
4. Turn off the lever of inclusion of 4/5th transfers (117).
5. Unscrew the shaft (103) 4/5th gear and remove the shift lever from the gearbox.
6. Remove the lever (5), plug (6) and clutch (15) 4/5th gears from the input shaft.
7. Remove intermediate shaft (40) from the gearbox. Check the countershaft for damage and wear.
8. Loosen the nut (111) with puck (111a) and remove your finger (106) with locking lever (107), sleeve (108), leaf spring (109) and gasket (110).
9. Remove friction ring (126) and needle bearing (125) from the drive shaft (2).
10. Unscrew the front cover of the gearbox (92).
11. Remove the drive shaft (2) with ball bearing (43) and gaskets (43a) forward.
12. Remove the bearing outer race (97) using a punch.
Axial clearance adjustment
1. Install the drive shaft (2) with ball bearing (43) and gaskets (43a) into the gearbox housing using a punch.
2. Install the intermediate shaft, driven shaft, intermediate plate, rear and front transmission covers. After installing the drive shaft, fix the transmission front cover (92b) two bolts (arrows) so that the drive shaft does not fall out of the gearbox housing when installing the driven shaft.
3. Set the axial clearance of the input shaft (2) within 0-0.1 mm. To do this, measure the distance from the edge of the bearing groove (43) to the mating surface of the gearbox using a caliper.
4. Measure the distance from the mating surface of the front cover (92) To (4) flat surfaces (arrows) bearing housing.. The shortest distance must be taken for measurement. If the bearing housing is bolted to the front cover, measure the depth from the mating surface to the groove. Calculate the required washer thickness: Depth (7.00 mm) - Clearance (6.50 mm) = Difference (0.50 mm) = Washer thickness (0.50 mm). Washers 0.2, 0.3, 0.5 mm thick are produced.
5. Set the axial clearance of the intermediate shaft within 0-0.05 mm. To do this, measure the depth of the groove from the mating surface of the gearbox front cover (92).
6. Remove the outer race (97) countershaft bearing with a drift, turning the shaft until the tapered roller bearing is seated correctly.
7. Measure the distance from the edge of the outer race (97) to the mating surface of the gearbox (see resist. illustration). Determine the thickness of the gaskets: Depth (2.47 mm) - Clearance (2.21 mm) = Difference (0.26 mm) - Clearance (0.05 mm) = Gasket thickness (0.21 mm). Gaskets are available in thicknesses of 0.2, 0.22, 0.25, 0.27, 0.3, 0.32, 0.35, 0.37 and 0.5 mm.
8. Install gaskets (94) And (96) in the front cover of the gearbox (92) and fix them with grease (see illustration 19.10).
9. Lubricate the mating surfaces of the front cover with sealant 002 989 00 20 (Loctite 573) and install the cover (92) to the drive shaft. Remove grease from the head of the bolts and grease them with sealant 001 989 25 20 (Hylomar).