2. Press the sleeve for the 5th gear needle bearing onto the drive shaft.
3. Install the drive shaft (2) and driven shaft (1) with the radial ball bearing bracket into the pressure piece (T10085) as shown in the figure below.
4. Install the gear shift mechanism (gear shift forks) (4) into the sliding shaft couplings as shown in the figure below.
5. Install the reverse gear shaft (3) shown in the figure below together with the reverse gear.
6. Screw the guide pin (T10079) onto the reverse gear axle support (arrow) as shown in the figure below.
7. Install the parts together into the gearbox housing, inserting the guide pin (T10079) through the gearshift mechanism mounting hole in the gearbox housing, as shown in the figure below.
8. Unscrew and remove the guide pin (T10079).
9. Before pressing in the bearing bracket, check that the gear 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.
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11. Screw in the screw (A) of the reverse gear shaft support shown in the figure below.
12. Install the bearing journals (B) on the underside of the gearbox as shown in the figure below.
13. Install the reverse switch "F4" (C) shown in the figure below.
14. Install the bearing journals (B) onto the top side of the gearbox.
15. Set the gear shift forks to neutral position.
16. Apply sealant (AMV 188 200 03) evenly onto the sealing surfaces of the gear shift cover.
17. Install the gear shift control shaft with the gear shift cover (A). Tighten the mounting screws (arrows) as shown in the figure below.
18. Screw in new fastening screws (A), tighten the bearing bracket of the drive and driven shafts.
Note: Tighten the screws gradually in a crosswise pattern, applying the appropriate tightening torque.
19. Tighten the hex nut (B) of the gear shift mechanism (gear shift forks).
20. Install the differential assembly into the clutch housing.
21. Apply sealant (AMV 188 200 03) evenly onto the sealing surfaces.
22. Connect the clutch housing to the gearbox housing.
23. Turn the gearbox in the assembly stand with the gearbox housing facing up.
24. Install the 5th gear carriage gear (1) as shown in the figure below.
Position for assembling the gear for 5th gear:
The belt (arrow) is directed towards the gearbox housing cover.
25. Install the 5th gear pinion with needle bearing.
26. Install the 5th gear synchronizer locking ring onto the gear carriage.
27. Install the 5th gear synchronizer carriage together with the sliding sleeve and thrust ring.
28. Install the 5th gear engagement fork (2), install the bearing journal (1) until it stops, as shown in the figure below.
29. Determine the dimensions of the new retaining rings (arrow).
30. Install the thickest drive shaft retaining ring (3) and the thickest driven shaft retaining ring (4) that can still be installed, as shown in the figure below.
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31. Install the gearbox housing cover assembly.
32. Mount both drive shafts with flange with springs, thrust rings and tapered rings 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 transmission oil.
