1. Install the input shaft (2), output shaft (1) together with the bearing support in a special fixture (T10080), as shown in the figure below.
2. Insert the gear shift forks (4) onto the fork rods as shown in the figure below.
3. Install the shaft together with the reverse gear pinion (3).
4. Screw the guide bolts of the special tool (T10079) into the reverse gear shaft mounting bolts (arrow), as shown in the figure below.
The fifth gear is not installed on the gearbox output shaft
5. Install the drive (2) and driven (1) shafts together with the bearing support in a special fixture (T10080), as shown in the figure below.
6. Install the gear shift forks (4) onto the fork rods as shown in the figure below.
7. Install the reverse gear pinion shaft (3) together with the pinion.
8. Screw the guide bolts (T10079) onto the reverse gear pinion mounting bolts (arrows) as shown in the figure below.
Continued for all cars
9. Install the components into the transmission housing by inserting the guide bolt (T10079) through the gear selector locking mechanism holes in the transmission housing as shown in the figure below.
10. Unscrew the guide bolt (T10079).
11. Before pressing on the gearbox shaft bearing support, check:
Correct installation of the gear shift forks. Make sure that they move freely on the rod bushings.
Measure the length of gear "a" shown in the figure below.
Note.
- Output shafts of different gearboxes may have different "a" values.
- The length of "a" should be 30.6 mm.
12. Install the washer (T10083/1) on the gearbox drive shaft as shown in the figure below.
13. Carefully press in the bearing support together with the drive and driven shafts as shown in the figure below.
14. Tighten the reverse gear shaft mounting bolt (A) shown in the figure below.
15. Install the axle pins (B) of the lower part of the gearbox as shown in the figure below.
16. Screw in the reverse gear light switch (C) as shown in the figure below.
17. Install the axle pins (B) from the top of the gearbox housing as shown in the figure below
18. Set the gear shift forks to neutral position.
19. Apply an even layer of sealant (AMV 188 200 03) on the sealing surface of the gearbox cover.
20. Install the gear selection and engagement mechanism shaft (A). Tighten the mounting bolts (arrows) in turn as shown in the figure below.
Cars with start-stop system
21. Insert and secure the gearbox neutral gear engagement mechanism (arrow) with the mounting bolt, as shown in the figure below.
For all cars
22. Install and tighten the transmission shaft bearing support mounting bolts (A) as shown in the figure below.
Note: Gradually tighten the mounting bolts (A) to the required tightening torque in several passes, crosswise, starting with the central bolts.
23. Engage the nut (B) of the gear selection and engagement mechanism as shown in the figure below.
24. Install the input and output shafts of the gearbox together with the bearing support on the special device (T10083), as shown in the figure below
Installing the fifth gear manually
25. The upper sleeve (arrow) points towards the gearbox cover. Install the fifth gear pinion (1) and sleeve (2) if the pinion is installed without pressing.
26. Install the fifth gear (1) and bushing assembly (2) as shown in the figure below.
Pressing on the fifth gear pinion
27. Using a set of special tools and a hydraulic press, press the fifth gear (1) onto the gearbox shaft, as shown in the figure below.
28. Install the sleeve on the fifth gear (2).
Continuation for all versions
29. Install the fifth gear sliding clutch together with the fifth gear synchronizer ring and needle bearing.
The figure below shows the installation position for the 5th/6th gear synchronizer. The outer sleeve (arrow) points toward the 5th gear pinion and toward the gearbox housing.
Press on the 5th/6th gear synchronizer sliding sleeve if the fifth gear pinion (1) is installed on the shaft together with the bearing and synchronizer ring.
Attention: Put on gloves before starting the operation.
30. Heat the inner ring of the sixth gear needle bearing to a maximum of 100 degrees Celsius, then press it onto the gearbox shaft.
31. Install the sixth gear synchronizer ring.
32. Install the sixth gear pinion together with the needle bearing as shown in the figure below.
Attention: Use protective gloves to perform the operation.
33. Heat the inner ring of the cylindrical roller bearing (A) to 100 degrees Celsius, then press it onto the gearbox drive shaft as shown in the figure below.
34. The figure below shows the installation position of the sixth gear pinion. The protrusion of the larger sleeve is directed towards the fifth gear pinion
35. Move the sliding sleeve (A) of the fifth-sixth gear synchronizer to the neutral position. This will allow the freely rotating sixth gear pinion to rotate freely while the pinion is pressed onto the output shaft.
Attention: To perform this operation, it is necessary to use special protective gloves.
36. Heat the sixth gear to a maximum of 100 degrees Celsius.
37. Press the sixth gear onto the gearbox shaft, making sure that the teeth of the freely rotating (B) and tightly fitted (C) gears are engaged as shown in the figure below.
38. Heat the inner race of the cylindrical roller bearing (A) to a maximum of 100 degrees Celsius, then press it onto the output shaft of the gearbox as shown in the figure below.
39. Install the differential assembly with the final drive driven wheel (A) into the gearbox housing, as shown in the figure below.
40. Apply a special sealant (AMV 188 200 03) evenly on the mating surfaces.
41. Install the clutch housing onto the gearbox housing assembly.
42. Turn the gearbox assembly on the stand and install it with the clutch housing facing up.
43. Before finally tightening the mounting bolts (A), it is necessary to engage fifth gear by moving the synchronizer to the stop (arrow 1) and first gear by turning the gear selection and engagement lever (arrow 2 and 3), as shown in the figure below. This will lock both gearbox shafts.
44. Insert the fifth-sixth gear shift forks (2) and press the axle bolt (1) until it stops in the direction of the arrow, as shown in the figure below.
45. Apply a uniform layer of special sealant to the mating surface on the gearbox housing.
46. Install the gearbox housing cover. Install and tighten the cover mounting bolts to the required tightening torque.
47. Install both flanges of the right and left drive shafts together with the pressure springs, thrust discs and conical rings. Tighten the flange fasteners to the required tightening torque.
48. Install the gear release fork together with the release bearing.
49. Fill the gearbox with the recommended transmission oil.