Assemble From Components

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




1. Place the clutch case in a suitable overhaul stand with fixture tool No. 87 92 228, or equivalent, and spacing sleeves.
2. Scrape off old residues of sealant from the parting surface.
- Also clean any sealant residues from the gear case.




3. Place the differential in the clutch case.
- Note the notch in the differential against the bulge by the output shaft's bearing support.




4. Place the output shaft in its seat and install the bearing race with a plastic hammer.
- Insert the bearing support and tap down with a plastic hammer and bearing race assembly sleeve tool No. 87 92 202 and sleeve tube tool No. 87 91 204, or equivalents.
- Install the screws and tighten the three screws in the middle alternately with a torque of 33-43 Nm (24-32 ft. lbs.). Note that the outermost screw should only be tightened with 20-24 Nm (14.5-17.5 ft. lbs.).




5. Install the 1st and 2nd gears' gear wheels with their synchromesh unit (which have been previously assembled) on the output shaft with output assembly tool No. 87 92 103, or equivalent.
- Install the 3rd gear's gear wheels and spacing sleeve on the output shaft.
- Do not let the installed gear wheels come too far down the shaft, leave 15 mm, otherwise, it will not be possible to install the input shaft.
6. Place the input shaft in the case.
- Install a tie strap to keep input and output shafts' teeth engaged (refer to illustration).




7. Press down the gear wheels on the output shaft towards the surface on the clutch case.
- Tap with a plastic hammer and sleeve tube tool No. 87 91 204 and driver ring tool No. 87 90 867, or equivalent, until it is possible to insert ANOTHER CLAMPING SLEEVE and the 4th gear's gear wheel.
- Turn the 4th gear's gear wheel so that the machining marks face upwards.




8. Install screw press tool No. 87 91 261, or equivalent, and pull down until the 4th gear's pinion and gear wheels on the input and output shafts are level with each other.
- Cut off the clamping tie strap and remove output shaft assembly tool.




9. Slightly lift the input shaft and install the reverse gear with its pinion and synchromesh.
- The hole in the reverse shaft should be facing the channel in the clutch case.




10. Install the gear change mechanism in the clutch case with the 1st gear's fork in 1st gear's position on the gear change mechanism and push up the sleeve towards the 2nd gear's synchromesh position on the output shaft.
- Push up the sleeve in the 4th gear's synchromesh position on the input shaft.
11. Install 1st-2nd gears' and 3rd-4th gears' forks in their sleeves.
- Turn and push the mechanism into place.
- Disengage 1st gear by lifting up the fork with a screwdriver.
- Insert the guide sleeves and install one of the screws.




12. Install the reverse gear lever with the two remaining screws.
- Tighten the three screws (reverse gear lever and gear change mechanism share one screw) with a torque: of 20-24 Nm (14.5-17.5 ft. lbs.) .
- The reverse gear lever's two screws are 20 and 50 mm long.
- The longer screw (50 mm) is shared by the reverse gear lever and the gear change mechanism.

NOTE: The oil plate of the reverse gear lever should be installed under the edge of the gear change mechanism.




13. Install the fork on the reverse gear's sleeve.
- Ensure that the reverse gear lever enters the grooves of the reverse gear fork.
- Then push in the fork shaft.
- Engage reverse gear on the gear change mechanism.




14. Place gear selector shaft in position, sparingly lubricated with Mobile Grease 57C or Shell Grease 1344 LIEP II, or equivalent.

NOTE: Turn the gear selector shaft with the bevelled hole facing upwards.

15. Thread in and install the carrier in place, push in the gear selector shaft and install the screw to of 20-24 Nm (14.5-17.5 ft. lbs.) .
16. Hold down each shaft and test by changing gear.
- Then engage 3rd or 4th gear.

NOTE: If a bearing on the output shaft or differential has been replaced, the seal holder must be removed and the differential bearing race pressed out of the gear case for later measuring of the differential preload.




17. Sparingly apply Loctite 518, or equivalent, to the contact surfaces of both the gear box case and the clutch case.
- Brush out the Loctite and allow it to dry for a couple of minutes.

CAUTION:

- Be very careful when assembling the gearbox and applying sealer.
- If the sintered insert (by the arrow in the illustration above) in the gearbox ventilation is blocked, the oil in the gearbox could be forced out.




18. Ensure that the reverse shaft support is correctly placed, so that the screw can be installed after the gear case has been installed.
- Place the gear case on the clutch case.

NOTE: Cover the holes in the gear case, so that nothing can enter the gearbox by mistake.




19. First secure the clutch case and the gear case lightly with two screws.
- Then tap up the guide sleeves.
- Install the screw for the reverse shaft; if necessary, push it with a narrow screwdriver to guide the screw hole to the hole in the gear case.
- Install remaining screws.
Tightening torque: 20-24 Nm (14.5-17.5 ft. lbs.)




20. Install the bearing on the output shaft and pull it down with the screw press tool.
- Do not pull it all the way down to the bottom against the outer bearing race.




21. Install the 5th gear wheel on the output shaft.
- Tap down the 5th gear wheel, if necessary, with a plastic hammer and sleeve tube tool so that the screw press can be installed.
- Use the screw press tool to pull down the gear wheel.
- Install a new nut.
22. Install the 5th gear's pinion with its needle bearing, synchromesh, synchromesh hub and sleeve on the input shaft.
- The stop heels of the baulk ring should be positioned over the holes in the hub.
- It might be necessary to tap down the hub on to the input shaft's splines-joint using the sleeve tube tool and a plastic hammer.




23. Install dial indicator tool No. 87 92 1 94 with stand tool No. 87 90 727, or equivalents.
- Engage 3rd gear and push down the 5th gear's sleeve to "lock" the gearbox.
- Tighten the nut and measure alternately with the dial indicator until there is an axial play of 0.15-0.20 mm on the output shaft.
- Use a short 8 mm screw in the sealing surface as a fixed point.
- Lift out the 5th gear's sleeve.

NOTE:

- Do not lift directly below the teeth, insert the screwdriver properly.
- Do not forget to remove the 8 mm screw.




24. Place the dial indicator's measuring end on the shaft shoulder.
- Disengage the gear and install the 5th gear's sleeve.
- Install driver tool No. 87 92 053, or equivalent, on the output shaft and "run" the gearbox with an electric drill so that the bearings "settle".
- Press and pull the drill and run about 20 revolutions, both pressing and pulling.
- Remove the tool.
- Record the reading of the axial play and then add the nominal value. Swing out the dial indicator.

Nominal Value, Output Shaft:
- Old case (over 50,000 km): 0.12 mm
- Old case (over 50,000 km): 0.12 mm
- Old case up to 50,000 km: 0.15 mm
- Old bearing, up to 50,000 km: 0.15 mm
- Old case, up to and over 50,000 km: 0.20 mm
- New bearing: 0.20 mm
- New case: 0.26 mm
- New bearing: 0.26 mm

Example: Measured value 0.23 mm + 0.20 mm (nominal value) = 0.43 mm.




25. Install the 5th gear's sleeve and engage 5th gear by pressing down the sleeve.
- Ensure that the high heels on the sleeve rest against the deep tooth gaps on the synchromesh hub.
- Engage 3rd gear.




26. Install tool millimeter disc tool No. 87 92 061, or equivalent, on the output shaft's nut.
- Mark up one tooth on the gear wheel with a felt tip pen or similar.
- Set the millimeter disc tool's scale to the calculated value (measured + nominal, see example).




27. Tighten in 2-3 stages until the millimeter disc tool's zero reading (O) is opposite the marked tooth.
- Upset the nut collar in three places on the 5th gear wheel to lock the nut.
- Remove tool and sleeve.




28. Lift off the 5th gear's pinion, synchromesh, synchromesh hub and sleeve.
- It might be necessary to use a puller to remove the hub.




29. If a bearing on the output shaft has been replaced or if differential bearings have been replaced, the differential's preload must be checked and if necessary be adjusted as follows.
- If not, go to step/item 33.
- Install tool machined races tool No. 87 92 137, or equivalent instead of the bearing race which was previously pressed out.
- Remove the bearing support's O-ring.
- Insert a packet of shims of about 1.2 mm together with the bearing support.




30. Place the 10 kg weight tool No. 87 92 095, or equivalent, on the bearing support.
- Install driver tool No. 87 92 053, or equivalent, on the output shaft.
- Use an electric drill to run the differential at least 20 revolutions.
- Measure the play with a feeler gauge in three (3) places between the bearing support and the gear case.
- Take the mean value of the three readings and adjust to a value of:

Nominal Value Differential:
- Old case (50,000 km) w/ old bearing (50,000 km): 0.20 mm
- Old case (50,000 km) w/ new bearing (50,000 km): 0.30 mm
- New case w/ new bearing: 0.35 mm

NOTE:

- Thicker shims = Increase the preload.
- Thinner shims = Reduce the preload.
- Shims for the differential are available in the following sizes: 0.10, 0.15, 0.30 and 0.50.

31. Remove the 10 kg weight, differential bearing support and machined bearing race.

CAUTION:
- Do not forget to remove machined bearing race tool and replace it with the bearing race.
- Risk of damage to the gearbox.




32. Insert the bearing race with a plastic hammer.
- Install and lubricate the O-ring on the bearing support.
- Install the screws and pull down the bearing support and measure the packet of shims with the bearing support.
- Tighten alternately to 20-24 Nm (14.5-17.5 ft. lbs.).
- Remove the driver tool from the output shaft.




33. Install the driver tool tool 87 91 428 on the input shaft.
- Place the measurement tip of the dial indicator on the bearing of the input shaft.
- Install an electric drill to the tool and "run" the gearbox to "settle" the bearings.
- Press and pull the drill and run about 20 revolutions, pulling and pressing.
- Measure the axial play.
- The axial play should be 0.04-0.11 mm.
- Adjust with shims under the bearing support if necessary.
- Thinner shims = less play
- Thicker shims = more play.
- Shims are available in the following sizes: 0.10, 0.15 and 0,30.
34. When adjusting the axial play on the input shaft:
- Remove the four screws on the bearing support.
- Install the bearing support together with the correct packet of shims and tighten alternately to 33-42 Nm (24-32 ft. lbs.).
- Measure the play again.

NOTE: If the play is too small, the gear case must be removed and the bearing race pressed out again.

- Remove the three tools.




35. Check that 3rd gear is engaged.
- Install the 5th gear's pinion, baulk ring and synchromesh hub.
- The stop heels of the baulk ring should be placed opposite the holes in the hub.
- It might be necessary to tap down the hub with sleeve tube tool and a plastic hammer.




36. Install the 5th gear's fork on its sleeve.
- Install fork and sleeve.
- The sleeve should be installed with the high heels against the synchromesh hub's deep teeth gaps.
- Install a new locking ring.
37. Drive in the clamping pin in the gear change shaft.




38. Remove the cover over the gear case's holes.
- Install a new gasket and the end cover.
- Tighten the screws to 20-24 Nm (14.5-17.5 ft. lbs.).
39. Test the gear change mechanism by engaging all gears one by one.




40. Install the oil drain plug and seal with thread sealing liquid.
- Tighten to 45-55 Nm (33-41 ft. lbs.).
- Check that the magnet is in place in the plug.




41. Grease the clutch release shaft by the bushes with Molycote X5-7521, or equivalent lubricant, before installing.
- Install the release bearing, fork, shaft and screw.
- Sparingly grease the support sleeve, release bearing and splines on the plate/shaft with Shell RETINAX AM or Molycote Rapid G or equivalent lubricant.
- Tighten the screw for the fork to 23-27 Nm (16-20 ft. lbs.).
42. Oil should not be poured in until after the drive shafts have been installed on the gearbox and the gearbox installed into the car.
- Amount of oil: 1.9 liters.
- Reconnect the reverse light switch with a new seal after the gearbox has been installed into the car.
Reverse light switch tightening torque: 20-24 Nm (14.5-17.5 ft. lbs.)