Disassemble To Components

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





NOTE:
- Before the gearbox is dismantled:
- The oil in the gearbox should be drained
- The rear light switch should be removed to prevent it from being damaged
- The linkage and bracket should be removed.
- Cover the hole for the switch.
- After the outside of the gearbox has been cleaned, work should commence as follows




1. Place the gearbox in a suitable overhaul stand with holder tool No. 87 92 228, or equivalents.
- Cover the holes for the differential.




- Remove the screw to the fork for the clutch bearing.




- Pull out the shaft and save the fork and the clutch bearing.




2. Unscrew and remove the end cover and gasket.
3. Engage 3rd or 4th gear to lock the gearbox and to prevent the latch balls of the gear changing mechanism from coming out.




4. Tap out the latch pin for 5th gear selector fork.
- Remove fork and sleeve, install sleeve.

NOTE: To facilitate reinstalling, mark with a marking pen the sleeve's position in relation to the 5th gear's synchromesh hub before removing the sleeve.




5. Press down the sleeve to engage 5th gear.
- Two gears must be engaged simultaneously when the nut on the output shaft is unscrewed.
- Note that the sleeve can only be placed in the synchromesh hub when the high heels on the sleeve are opposite the deeper tooth gaps on the synchromesh hub.
6. Using a drift, knock out the lock on the nut on the output shaft. Remove the nut.

NOTE: In all work with dismantling of the gearbox a new nut and a new clamping sleeve should be installed during assembly, because the clamping sleeve has lost its spring action.




7. Remove the locking ring for the 5th gear's synchromesh hub.
- Lift out the 5th gear's synchromesh hub with its sleeve and pinion.
- It might be necessary to use puller tool No. 87 91 287 with puller arms tool No. 87 91 303, or equivalents.




8. Remove the screw for the reverse gear's shaft support in the gear case.
9. Unscrew and remove the screws in the parting surface between gear case/clutch case.
- Tap down the two guide sleeves.




10. Screw on two hook eyes tool No. 87 92 129, or equivalent.
- Install shaft protector tool No. 87 91 410, or equivalent, on output shaft journal.
- Hook on puller tool No. 87 91 287 with puller arms tool No. 87 91 303, or equivalents, in the tools and pull the case out carefully.
- First check that 3rd or 4th gear is engaged.
11. Press out the gear case with its gears and bearings.
- Remove the tools.




12. Remove fork shaft and gear selector fork for reverse gear.




13. Unscrew and remove the reverse gear lever.

NOTE:
- The two screws are not standard length (45 mm).
- One is 20 mm long and the other is 50 mm long.

14. Engage reverse gear on the gear change mechanism to gain access to the screw for the gear selector shaft.




15. Remove the screw for the carrier on the gear selector shaft.
- Pull out the shaft and put the carrier in a safe place.




16. Engage 4th gear on the gear change mechanism.
- Remove the screw and lift up the gear change mechanism slightly, so that the guide sleeves come out of their positions.
- Remove the sleeves.
- Pull the gear change mechanism backwards towards the differential and swing it out slightly.
- Lift out the gear change mechanism.




17. Slightly lift the input shaft and lift up the reverse gear shaft with its pinion (the reverse gear).




18. Place puller tool No. 87 91 287 with puller arms tool No. 87 91 295, or equivalent, under the 1st gear wheels on the output shaft.
- Place protective sleeve tool No. 87 91 410, or equivalent as a protection on the output shaft journal.
- Tighten slightly and install output shaft assembly tool No. 87 92 103, or equivalent, which holds the 1st and 2nd gears' synchromesh unit together.
- Install a securing tie strap around the tool and pinion unit.
- Pull up all the gear wheels on the output shaft about 15 mm.
19. Lift out the output shaft.
20. Continue to pull until the gear wheels on the output shaft come loose.




21. First lift off the 4th gear wheels, clamping sleeve, spacing sleeve and 3rd gear wheels.
- Then lift out the rest of the gear wheels (1st and 2nd), baulk rings and sleeve which are held together by an output shaft assembly tool.




22. Remove the four screws and remove the output shaft's bearing support.




23. Pull up the output shaft.
- Use screw press tool No. 87 91 188, assembly ring tool No. 87 91 972 and sleeve tube tool No. 87 91 261, or equivalents.




24. Lift out the differential by setting the notch in the differential against the bulge by the output shaft's bearing support.