Pic. 3.8. Manual transmission components: 1 - back cover; 2 - locknut; 3 - retaining ring; 4 - gearbox housing; 5 – stopper of a clamp, a spring and a ball; 6 – a shaft of an intermediate gear wheel of a backing; 7 – an intermediate gear wheel of a backing; 8 – a fork of inclusion of a reverse gear assy; 9 - wings (spring) switching on the reverse gear; 10 – reverse gear engagement lever; 11 - limiter for reverse gear engagement; 12 – the switch of lanterns of a backing; 13 - driven gear of the speedometer drive; 14 - blocking pin; 15 – a rod of a fork of switching of 1–2 transfers; 16 - shift fork 1-2 gears; 17 – a tip of a rod of a plug of switching 1–2 transfers (shift head 1-2 gears); 18 - blocking pin; 19 – a rod of a fork of switching of 3–4 transfers; 20 - shift fork 3-4 gears; 21 – a tip of a rod of a plug of switching 3–4 transfers (shift head 3-4 gears); 22 - blocking pin; 23 – a rod of a fork of switching of 5-back transfers; 24 - shift fork 5-reverse gear; 25 - a tip of a rod of a fork of a shift of 5-reverse gears (5-reverse shift head); 26 - input shaft; 27 - output shaft; 28 - bearing cover; 29 - differential assembly; 30 - magnet; 31 - stuffing box; 32 - clutch housing
Disassembly
Pic. 3.9. Back cover
Remove the rear transaxle case cover, locknut and circlip (pic. 3.9).
Remove the retainer plug, spring and ball.
Pic. 3.10. Reversing light switch
Remove the reversing light switch (pic. 3.10).
Remove the fixing bolts of the rear housing and the main housing.
Remove the reverse idler shaft and reverse idler gear.
Pic. 3.11. Removal of the limiter of inclusion of transfer of a backing
Remove the backstage (spring) reverse gear engagement (pic. 3.11).
Pic. 3.12. Fork of inclusion of a reverse gear assy
Remove the reverse gear engagement limiter and reverse gear fork assembly (pic. 3.12).
Pic. 3.13. Extraction of the locking pin from the fork and the tip of the rod assembly with punching the pin
Carefully remove the locking pin from the yoke and stem end assembly with punched pin (pic. 3.13).
Pic. 3.14. How to remove the locking pins
Remove all locking pins, the location of which is shown in the figure (pic. 3.14).
Pic. 3.15. 5-reverse shift fork stem, 5-reverse shift fork and 5-reverse shift fork stem tip
Remove the 5-reverse shift fork stem, 5-reverse shift fork and 5-reverse shift fork stem tip (pic. 3.15).
Pic. 3.16. Fork stem and shift fork 3-4 gears
Remove the 3-4 shift fork stem, 3-4 shift fork and 3-4 shift fork stem tip (shift head 3-4 gears) (pic. 3.16).
Pic. 3.17. Fork stem and shift fork 1-2 gears
Remove the 1-2 shift fork stem, 1-2 shift fork and 1-2 shift fork stem tip (shift head 1-2 gears) (pic. 3.17).
Remove the gears and synchronizer assembly of the input and output shafts in the sequence shown, and then remove the main shaft (Remove the gears and clutches of the synchronizers of the input and output shafts).
Pic. 3.18. output shaft
Remove the rings, bearings and synchronizer sleeve assembly of the input shaft. Remove the four bearings and remove the output shaft (pic. 3.18).
Remove the differential assembly.
Pic. 3.19. Removing the differential
Remove the speedometer drive gear after removing the bolt (pic. 3.19).
Pic. 3.20. Removing the input shaft seal
Remove the input shaft seal using a screwdriver or suitable tool (pic. 3.20).
Remove the stuffing box cover.
Remove the reverse gear limiter oil seal using a screwdriver or suitable tool.
Pic. 3.21. Removing the input shaft seal
Remove the differential seal using a screwdriver or suitable tool (pic. 3.21).
Assembly
Pic. 3.22. Installing the drive shaft seal
Install the drive shaft seal (pic. 3.22).
Pic. 3.23. Installation of gearbox bearings
To assemble the gearbox bearings and install the differential housing, use the special tool (pic. 3.23).
Pic. 3.24. Installing the differential seal
Install the differential seal (pic. 3.24).
Install the speedometer drive gear.
Pic. 3.25. Setting the differential
Install the differential in the clutch crater (pic. 3.25).
Install the input and output shafts in the clutch crater.
Pic. 3.26. Installation of input and output shaft gears
Install the gears and synchronizer clutch assemblies of the input and output shafts (pic. 3.26).
Install the 1-2 shift fork stem, 1-2 shift fork and 1-2 shift fork stem tip (shift head 1-2 gears).
Install the 3-4 shift fork stem, 3-4 shift fork and 3-4 shift fork stem tip (shift head 3-4 gears).
Install the 5-reverse shift fork stem, 5-reverse shift fork and 5-reverse shift fork stem tip.
Pic. 3.27. How to install the locking pins
Install the yoke lock pins and yoke stem assemblies in the order shown in the figure (pic. 3.27).
Install the reverse shift fork assembly and reverse shift stop and tighten with two reverse shift fork bolts.
Install the reverse gear lever and tighten with two reverse gear lever bolts.
Install backstage (spring) engaging reverse gear.
Pic. 3.28. Reverse idler shaft and reverse idler gear
Install the reverse idler shaft and reverse idler gear (pic. 3.28).
Attach the magnet to the clutch crater.
Pic. 3.29. Gearbox mounting bolts
Secure the gearbox with mounting bolts (pic. 3.29).
Install the reversing light switch.
Install plugs, seats, springs and balls.
Install the output shaft locknut.
Install the back cover.