Contents: Gearbox - overview of parts ⬇ Harvesting scheme ⬇ I - Removing and installing the…⬇ I - Removing and installing the…⬇ Removal and installation the drive…⬇ Repair of the gearbox housing and…⬇ Disassembling and assembling the…⬇ Disassembling and assembling gear…⬇
Gearbox - overview of parts
1 - 1st gear (speed); 2 - 2nd gear (transmission); 3 - 3rd speed stage (gear).; 4 - 4th gear (gear); 5 - 5th gear (speed); 6 - gearbox housing; 7 - gear shift drive, gear shift forks; 8 - drive gear for 1st gear, reverse gear; 9 - drive shaft; 10 - driven shaft; 11 - differential; 12 - clutch housing
Harvesting scheme

- I - Removing and installing the gearbox housing cover and 5th gear
- II - Removing and installing the gearbox housing and gear shift drive
- III - Removing and installing the drive shaft, driven shaft, differential and gear shift forks
I - Removing and installing the gearbox housing cover and 5th gear
Important: If a transmission cover is installed on a vehicle's integrated gearbox, the transmission oil level must be checked and topped up if necessary.
1 -14 Nm; 2 - Gearbox housing cover; 3 - Seal; 4 - Bolt M10, 80 Nm, holds the disc spring, always replace; 5 - Disc spring; 6 - 25 Nm, for supporting the journal on the gearbox housing; 7 - Bearing journal; 8 - Gear shift fork for engaging 5th gear; 9 - Spring; 10 - Sliding clutch for 5th gear; 11 - Synchronizer locks (3 pieces); 12 - Synchronizer carriage with gear and locking ring of 5th gear synchronizer; 13 - Needle bearing; 14 - Gear for 5th gear
I - Removing and installing the gearbox housing and gear shift drive
1 - 25 Nm; 2 - Shaft with flange and compression spring; 3 - 25 Nm, for supporting the reverse gear axle; 4 - 30 Nm, for supporting the reverse gear axle; 5 - O-ring, always replace; 6 - Bearing journal; 7 - 22 Nm; 8 - 22 Nm; 9 - Cork; 10 - Gearbox housing; 11 - Clutch housing; 12 - 25 Nm and turn an additional 90° to secure the gearbox housing to the clutch housing; 13 - Gear shift mechanism; 14 - 22 Nm
Removal and installation the drive shaft, driven shaft, differential and gear shift forks
1 - Differential; 2 - O-ring, 4 pcs, always replace; 3 - Driven shaft; 4 - Reverse gear axle support; 5 - Reverse gear shaft; 6 - Drive shaft; 7 - Gear shift fork for engaging reverse gear; 8 - 25 Nm; 9 - Gear shift mechanism, gear shift fork; 10 - Clutch housing; 11 - 25 Nm and turn an additional 90°, 4 nuts for fastening the bearing; 12 - Shaft with flange and compression spring; 13 - 25 Nm
Repair of the gearbox housing and clutch housing
1 - Gearbox housing, in case of replacement: adjust the drive shaft and differential; 2 - Screw, 30 Nm; 3 - Needle bearing, for driven shaft; 4 - Adjusting shim, for drive shaft; 5 - Outer ring (cage) of tapered roller bearing, for drive shaft, in case of replacement: adjust drive shaft; 6 - Outer ring (cage) of tapered roller bearing, for driven shaft, in case of replacement: adjust the driven shaft; 7 - Adjusting shim for driven shaft; 8 - Outer ring (shell) of tapered roller bearing, for drive shaft, in case of replacement: adjust drive shaft; 9 - Needle bearing without inner ring (needle bearing housing); 10 - Centering sleeve, 2 pcs.; 11 - Clutch housing; 12 - Ball joint, 25 Nm; 13 - Guide sleeve with O-ring, the O-ring is secured on the guide sleeve. If the O-ring is damaged, replace the guide sleeve with the O-ring for the drive shaft; 14-18 Nm, always replace; 15 - Sealing ring, for right shaft with flange; 16 - Bushing, for the right oil seal, pos. 15; 17 - Bushing and seal, one-piece design, damaged seal should be replaced together with the bushing; 18 - Speedometer drive, 10 Nm, only for vehicles without ABS; 19 - 30 Nm, without magnet; 20 - Outer ring (cartridge) of tapered roller bearing, for differential, in case of replacement: adjust differential; 21 - Magnet, held by the crankcase joint plane; 22 - Outer ring (cartridge) of tapered roller bearing, for differential, in case of replacement: adjust differential; 23 - Adjusting shim, for differential; 24 - Sealing ring, for left shaft with flange
Disassembling and assembling the gearshift mechanism
1 - Gear shift control shaft; 2 - Thrust ring; 3 - Ball bushing; 4 - Gear shift drive cover, with gear shift control shaft position lock; 5 - Reverse switch, 20 Nm; 6 - Guide (intermediate) lever; 7 - Bearing sleeve; 8 - Sealing ring, fill the space between the working edges with sealing grease "G 052 128 A1"; 9 - Cap for removing air from the gearbox; 10 - 20 Nm, always replace; 11 - Gearbox control lever, install so that the place with the gap in the teeth fits into the gear shift control shaft, can be replaced with a built-in gear shift mechanism; 12 - Retaining ring, replace after each removal; 13 - 15 Nm, fixes the gear shift control shaft; 14 - Cork
Disassembling and assembling gear shift forks
1 - Bracket; 2 - Segment; 3 - Gear shift fork for engaging 5th gear; 4 - 1st and 2nd gear engagement lever; 5 - Reverse gear engagement lever; 6 - Ring; 7 - Retaining ring; 8 - Segment; 9 - Ball bearing; 10 - Gear shift fork for 3rd and 4th gears; 11 - Gear shift fork for 1st and 2nd gears; 12 - Segment; 13 - Support for the gear shift fork for engaging reverse gear; 14 - Sliding plug (mushroom-shaped); 15 - Spring; 16 - Gear shift fork for engaging reverse gear; 17 - 25 Nm; 18 - 5th gear shift jaw; 19 - 5th gear engagement lever; 20 - 3rd and 4th gear engagement lever
