Contents: Sequence of operations during…⬇ II - Removing and installing the…⬇ III - Removing and installing the…⬇ Repair of the gearbox housing and…⬇ Disassembling and assembling the…⬇ Disassembling and assembling gear…⬇
Sequence of operations during installation
- I - Removing and installing the gearbox housing cover and 5th gear
- II - Removing and installing the shift housing
- 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 transmission, the transmission oil must be checked and topped up if necessary.
1 - Gearbox housing, made of aluminum or magnesium; 2 - Gear carriage for 5th gear, assembly position - Symbol defining the position of the illustration; 3 - Retaining ring, always replace, determine thickness - Symbol identifying the position of the illustration; 4 - Seal; 5 - Gearbox housing cover; 6 - 5 Nm + turn 90°, always replace; 7 - Retaining ring, always replace, determine thickness - symbol indicating the position of the illustration; 8 - 5th gear synchronizer carriage with sliding clutch and thrust ring; 9 - Synchronizer locking ring for 5th gear; 10 - Gear carriage for 5th gear; 11 - Needle bearing, for 5th gear, replace together with the bushing - pos. 12; 12 - Bushing, for 5th gear needle bearing, replace together with needle bearing - pos. 11, remove together with bearing bracket for radial ball bearing; 13 - 5th gear engagement fork; 14 - Pin, for 5th gear engagement fork
II - Removing and installing the clutch housing
1 - Conical head screw, 25 Nm; 2 - Shaft with flange and compression spring; 3 - 5 Nm + turn 90°, always replace; 4 - Clutch housing, made of aluminum or magnesium; 5 - Gearbox housing, made of aluminum or magnesium; 6 - Clutch release lever, with guide sleeve and clutch release bearing; 7 - 5 Nm + turn 90°, always replace
III - Removing and installing the drive shaft, driven shaft, differential and shift forks
1 - Differential; 2 - Gearbox housing; 3 - Threaded oil drain plug, for crankcase made of: magnesium - 24 Nm, aluminum - 32 Nm; 4 - Shaft with flange and compression spring; 5 - Cone head screw, 25 Nm; 6 - 5 Nm + turn 90°, self-locking, always replace, for fastening the bearing bracket of the drive and driven shafts: radial ball bearing - pos. 16; 7 - 23 Nm, for gear shift mechanism - pos. 15; 8 - O-ring, always replace; 9 - Bearing journal; 10 - 5 Nm + turn 90°, always replace; 11 - Gear shift control shaft with gear shift drive cover; 12 - 5 Nm + turn 90°, always replace; 13 - Reverse switch - F4-, 25 Nm; 14 - O-ring, always replace; 15 - Gear shift mechanism, gear shift forks; 16 - Drive and driven shafts with a ball bearing bracket; after removal, the bearing mounting bracket must always be replaced; 17 - Reverse gear shaft, with support for reverse gear transmission; 18 - Reverse gear; 19 - 25 Nm + turn 45°, reverse gear supports, always replace
Repair of the gearbox housing and clutch housing
1 - Clutch housing, aluminum or magnesium, if replaced: adjust the differential; 2 - Oil seal for the drive shaft, release with a screwdriver; 3 - Ball joint, 20 Nm, lubricate with grease; 4 - Sealing ring, for shaft with flange on the right; 5 - Bushing for oil seal; 6 - Screw, for crankcase made of: magnesium - 24 Nm, aluminum - 32 Nm; 7 - O-ring seal, only for vehicles without ABS, always replace; 8 - Speedometer sensor, only for vehicles without ABS; 9 - 5 Nm + turn 90°, only for vehicles without ABS, always replace; 10 - Adjusting shim S2, for differential; 11 - Outer ring (carrier) of tapered roller bearing, for differential, in case of replacement: adjust differential; 12 - 5 Nm + turn 90°, always replace; 13 - Outer ring (cartridge) of tapered roller bearing, for differential, in case of replacement: adjust differential; 14 - Adjusting shim S1, for differential; 15 - Fitting sleeve, (2 pcs.); 16 - Gearbox housing, aluminum or magnesium, if replaced: adjust the differential; 17 - Threaded oil drain plug, for crankcase made of: magnesium - 24 Nm, aluminum - 32 Nm; 18 - Sealing ring, for left shaft with flange; 19 - Sleeve, for gear shift control shaft; 20 - Magnet, held by the crankcase joint plane; 21 - Lid; 22 - Retaining ring, installed in the roller bearing spline - pos. 25; 23 - Retaining ring, installed in the roller bearing spline - pos. 24; 24 - Roller bearing, for drive shaft; 25 - Roller bearing, for driven shaft; 26 - Plug inserted into the hole in the clutch housing
Disassembling and assembling the gearshift mechanism
1 - Sleeve for gear shift control shaft; 2 - Gear shift control shaft with gear shift drive cover, replace together; 3 - Guide (intermediate) lever; 4 - Bushing; 5 - Remove the sealing ring using a screwdriver as a lever; 6 - Cap for gearbox ventilation; 7 - Gearbox control lever, install so that the place with the gap in the teeth fits into the gear shift control shaft, possibly replaceable with a built-in gear shift mechanism; 8 - Nut, 20 Nm, self-locking, always replace; 9 - Retaining ring, always replace
Disassembling and assembling gear shift forks
1 - Shift fork for 3rd and 4th gears; 2 - Ball bearing; 3 - Bracket, always replace; 4 - Retaining ring; 5 - Ring; 6 - Gear shift segment for engaging 3rd and 4th gears; 7 - 5th gear engagement lever; 8 - 3rd and 4th gear engagement lever; 9 - 1st and 2nd gear engagement lever; 10 - Reverse gear engagement lever; 11 - Trunnion; 12 - Gear shift fork for engaging reverse gear; 13 - Reverse gear mount; 14 - Retaining ring; 15 - Shift fork for 1st and 2nd gears; 16 - Gear shift segment for engaging 1st and 2nd gears; 17 - 5th gear engagement fork; 18 - Gear shift segment for engaging 5th gear; 19 - Pin, for 5th gear engagement fork
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