2. Press the 5th gear needle bearing bush onto the drive shaft.
3. Install the drive shaft (2) and driven shaft (1) with bracket for deep groove ball bearings in thrust piece (Т10085), as shown in the figure below.
4. Install the gearshift mechanism (shift forks) (4) into the sliding sleeves of the shafts, as shown in the figure below.
5. Put on the reverse gear axle shown in the figure below (3) along with the reverse gear.
6. Screw on the guide pin (T10079) on the reverse gear axle support (arrow), as shown in the figure below.
7. Install the parts together in the gearbox housing, while pushing the guide pin (Т10079) through the hole to secure the shift mechanism in the gearbox housing, as shown in the figure below.
8. Unscrew and remove the guide pin (Т10079).
9. Before pressing in the bearing bracket, check that the shift forks fit correctly into the sliding sleeves.
10. Carefully press in the bearing bracket together with the drive and driven shafts until it stops, as shown in the figure below.
11. Screw in the screw (A) reverse gear axle support shown in the figure below.
12. Install bearing journals (IN) on the underside of the gearbox as shown in the figure below.
13. Install reverse gear switch -F4- (WITH), shown in the figure below.
14. Install bearing journals (IN) on top of the gearbox.
15. Set the shift forks to the neutral position.
16. Apply sealant (AMV 188 200 03) uniformly on the sealing surfaces of the gearshift cover.
17. Install the shift control shaft with the gear shift cover (A). Tighten the fastening screws (arrows), as shown in the figure below.
18. Screw in new fastening screws (A), tighten the bearing bracket of the input and output shafts.
Note. Tighten the screws progressively in a criss-cross pattern with the appropriate tightening torque.
19. Tighten the hex nut (IN) gear change mechanism (shift forks).
20. Install the differential assembly into the clutch housing.
21. Apply sealant (AMV 188 200 03) evenly on sealing surfaces.
22. Connect the clutch housing to the gearbox housing.
23. Turn the gearbox in the assembly stand with the gearbox housing up.
24. Install the 5th gear (1), as shown in the figure below.
Gear assembly position for 5th gear:
Belt (arrow) directed towards the gearbox housing cover.
25. Install the 5th gear with needle bearing.
26. Install the 5th gear synchronizer ring on the gear-carriage of the transmission.
27. Install the 5th gear synchronizer carriage with sliding sleeve and thrust ring.
28. Install the 5th gear fork (2), install the bearing journal (1) until it stops, as shown in the figure below.
29. Determine the dimensions of the new circlips (arrow).
30. Install the thickest circlip of the input shaft (3) and the thickest retaining ring of the driven shaft (4), that can still be installed, as shown in the figure below.
31. Install the gearbox housing cover assembly.
32. Mount both flanged drive shafts with springs, thrust washers and conical washers as shown in the figure below.
33. Install the clutch release fork with the clutch release bearing and guide sleeve.
34. Add the required amount of gear oil.