Pic. 7.2. Transmission Shaft Components
1. Nut; 2. Spring; 3. Thrust ring; 4. Synchronizer clutch; 5. Synchronizer spring; 6. Synchronizer hub; 7. Synchronizer hub cracker; 8. Synchronizer ring; 9. 5th gear; 10. Bearing; 11. Spacer; 12. Gasket (comes in various thicknesses); 13. Bearing; 14. Complete assembly of the input shaft; 15. Bearing; 16. Input shaft seal; 17. Release bearing guide sleeve; 18. Screw; 19. Backstage; 20. Bearing; 21. Gasket; 22. Bolt; 23. Output shaft; 24. 1st gear; 25. Synchronizer ring; 26. Synchronizer spring; 27. Retaining ring; 28. Synchronizer hub cracker; 29. Synchronizer hub; 30. Synchronizer clutch; 31. Gear 2nd gear; 32. Holder; 33. Friction ring; 34. Gear 3rd gear; 35. Synchronizer hub; 36. Synchronous Dutch sleeve; 37. 4th gear; 38. Bearing; 39. Retaining ring; 40. 5th gear; 41. Reverse gear shaft; 42. Reverse gear assembly; 43. Pin.
Pic. 7.3. Transmission Gear Select Components
1. Holder; 2. Cylindrical pin; 3. Fork of inclusion of 1st and 2nd transfers; 4. Working ledge; 5. Blocking part; 6. Shaft of a fork of inclusion of transfer; 7. Fork of inclusion of the 3rd and 4th gears; 8. Limiter pin; 9. Spring; 10. Sealing washer; 11. Bolt; 12. Working capture; 13. Shaft of a fork of inclusion of transfer; 14. 5th gear engagement fork; 15. Reverse lever pin; 16. Cylindrical pin; 17. Ball; 18. Reversing lever; 19. Protective cover roller leash; 20. Gland roller leash; 21. Roller leash; 22. Backstage; 23. Washer; 24. Bolt; 25. Backstage pin; 26. Gearshift lever; 27. Angle lever; 28. Corner arm pin; 29. Cylindrical pin; 30. O-ring.
Repairing a manual transmission is a difficult task for a beginner auto mechanic. In addition to having to remove and install a large number of small parts, you will need to accurately measure and, if necessary, adjust numerous gaps by selecting gaskets. Therefore, it is recommended to entrust the transmission bulkhead to a specialist or purchase an already restored unit.
However, a motorist with some experience, with special tools, may well sort out the transmission on his own. Work carefully and methodically so as not to miss anything.
The tools needed for reassembly are pliers to remove the inner and outer stop ends, bearing pullers, slip hammer, punch set, dial micrometer, and possibly a hydraulic press. In addition, you will need a large, sturdy workbench and a vise.
During transmission disassembly, carefully record where each component is located to facilitate subsequent reassembly.
Before disassembling the transmission, try to find out which of its components is malfunctioning (see Chapter «troubleshooting»).