Output shaft (five-speed gearbox)

Disassembly PROCEDURE 1. Press 1st gear 30 off output shaft 45 together with synchro blocking ring 32, thrust washer 29 and tapered roller bearing 28 (see illustration Gearbox type 085). 2. Remove needle bearing 31. 3. Remove circlip 33. 4. Press off gear 39 together with synchro blocking ring 38 and synchronizer 36. 5. Remove needle bearing 40. 6. Remove 3rd gear 41. 7. Remove circlips 42 and 43. 8. Remove 4th gear 44. 9. Press off roller bearing 46. Assembly PROCEDURE 1. Press tapered roller bearing 46 onto output shaft 45, applying force to the inner bearing race. 2. Install 4th gear 44. 3. Install circlips 43 and 42. 4. Install 3rd gear 41. 5. Lubricate needle bearing 40 and install it on shaft 45. 6. Check the clearance between synchro blocking rings 38 and 32 and their corresponding gears 39 and 30 (see subsection 5.2.2.1). 7. Install 2nd gear 39 and synchro blocking ring 38. 8. Press on the assembled synchronizer 36 (if the synchronizer was disassembled, see

subsection 5.2.2.2) so that the groove for the shift fork on the sliding sleeve of the synchronizer faces the 1st gear wheel, and the synchronizer keys engage the slots of the blocking ring. 9. Install the snap ring 33. 10. Install the synchronizer blocking ring 32, making sure that the synchronizer keys engage the slots of the blocking ring. 11. Lubricate the needle bearing 31 and install it on shaft 45. 12. Install the 1st gear 30. 13. Install the thrust washer 29. 14. Press on the tapered roller bearing 28, applying force to the inner race of the bearing.

Adjusting the Output Shaft Axial Play Warning Perform the adjustment after replacing any of the following parts: transmission case, clutch housing, output shaft or output shaft tapered roller bearings.

PROCEDURE 1. Press out the outer race 6 (see figure Clutch Housing) of the tapered roller bearing from clutch housing 2. 2. Remove adjusting shim 7 and install a shim 0.75 mm thick in its place. 3. Press the outer bearing race 6 into clutch housing 2. 4. Install the output shaft, join the clutch housing to the transmission case and tighten bolts 14 (see figure Transmission Case) to torque 25 N·m. 5. Rotate the output shaft several times to seat the bearings. 6. Install the transmission vertically, with the end of the shaft on the 5th gear side facing up. 7. Install support 1 (see figure Input Shaft Adjustment) with post 2 and dial indicator 3 on transmission case 7. 8. Place a ground plate 5 under the dial indicator foot 4 on the output shaft. 9. Move the output shaft axially from stop to stop and read the dial indicator. 10. Calculate the required adjusting shim thickness using the formula: S = 0.75 + S0 + 0.20, where S is the calculated thickness of the required adjusting shim, mm; S0 is the measured axial play, mm. 11. Select an adjusting shim of the required thickness from the sets supplied as spare parts. Available sizes: from 0.7 mm to 1.4 mm in steps of 0.05 mm. 12. Remove the dial indicator with post and support. 13. Disassemble the housings and press the bearing outer race out of the clutch housing. 14. Remove the 0.75 mm shim and install the selected adjusting shim. 15. Press in the bearing outer race. 16. Assemble the transmission and check again.