2. Undo the reverse sensor and remove it.

3. Adjust the retaining clip and remove the three-way connector.

4. Undo the screws (4a) and remove the clutch control coaxial actuator (4b).

5. Undo the screws (5a) and remove the gear selection and engagement unit (5b).

1. Undo the screws (1a), remove the sealant, working at the three points (1b) and remove the gearbox casing (1c) from the clutch casing (1d).

- Clean the support surfaces between the gearbox casing and the clutch casing thoroughly.

1. Using tools (1a) and (1b) remove outer races (1c) and thrust rings (1d) for the main shaft and the layshafts.

1. Undo the screw securing the rear bearing to the main shaft using the special tool for counter-torque.

2. Remove main shaft (2a), layshaft (2b) and selector forks (2c) from their housings.

3. Remove the second layshaft from its housing.

DISMANTLE THE CLUTCH CASING AS DESCRIBED BELOW.

1. Using tools (1a) and (1b) remove outer races for front bearings (1c) for the main and the layshafts.

2. Remove the main shaft sealing ring from the clutch casing.

1. Using the extractor (1a) and a suitable mallet (1b), remove the bearing for gear selector shaft (1c).

DISMANTLE THE MAIN SHAFT (A) AS DESCRIBED BELOW

1. On the hydraulic press, use tools (1) and (1b) to remove rear bearing (1c), 6th speed gear (1d), 4th speed gear (1e) and spacer (1f).

1. On the hydraulic press, use tools (1a) and (1b) to remove 3rd and 5th speed drive gear (1c) from main shaft (1d).

The main shaft should be supported at the bottom during this operation.

1. On the hydraulic press, using the tools (1a), (1b) and (1c), remove front bearing (1d).

The main shaft should be supported at the bottom during this operation.

PROCEED WITH DISMANTLING THE LAYSHAFT (B) AS DESCRIBED BELOW.

1. Remove the gear selector forks (1a) from the layshaft (1b).

2. Remove the rear bearing retaining ring.

1. On the hydraulic press using the tools (1) and (1b) remove the rear bearing (1c), the 4th speed gear (1d) and the needle bearing (1e).

1. Remove the 4th speed synchronizer ring assembly.

2. Remove the 3rd and 4th speed sliding engagement sleeve.

3. Remove the pre-synchronizer mountings.

1. Remove the sliding sleeve hub retaining ring.

1. Remove the 3rd and 4th speed sliding sleeve hub (1a), 3rd speed synchronizer ring assembly (1b) and 3rd speed driven gear (1c) using a hydraulic press and tool (1d).

The layshaft should be supported at the bottom during this operation.

2. Remove the needle bearing.

1. Remove the spacer retaining ring.

1. On the press, using the tool (1a), remove the spacer (1b), the presynchronizer mountings (1c), the sliding sleeve (1d), the reverse synchronizer rings (1e), the reverse gear (1f) and the needle bearing (1g).

1. Remove the front bearing retaining ring.

1. At the press, remove the front bearing using a suitable extractor.

The layshaft should be supported at the bottom during this operation.

DISMANTLE THE SECOND LAYSHAFT (C) AS DESCRIBED BELOW.

1. Remove the retaining ring.

1. On the press, using the tool (1a), remove the 6th speed gear and the bearing (1b) and the needle bearing (1c).

The second layshaft should be supported at the bottom during this operation.

1. Remove the synchronizer retaining ring.

1. On the press, using the tool (1a), remove the 5th and the 6th speed synchronizer (1b) and the 5th speed gear (1c).

1. Release the needle bearing (1a) and remove the spacer (1b), the two half rings (1c), the 2nd speed gear and nthe eedle bearing (1e).

1. Remove the retaining ring (1a) and the 1st and the 2nd speed synchronizer rings (1b).

1. On the press, using the tool (1a), remove the 1st and the 2nd speed synchronizer (1b) and the 1st speed gear (1c).

1. Remove the bearing with double row of rollers.

1. At the press, remove the front bearing using a suitable extractor.

The second layshaft should be supported at the bottom during this operation.

Removing

REASSEMBLE THE SECOND LAYSHAFT (C) AS DESCRIBED BELOW.

If the bearing, the 1st speed gear or the presynchroniser are replaced, the thickness of the new calibrated retaining ring must be calculated as described below. Calculate the difference in thickness between the old and new components. The value of the difference should be added to or subtracted from the thickness of the retaining ring removed to determine the thickness of the new retaining ring that should be fitted. A retaining ring set is available from Parts.

1. Position the two bearings (1a), the 1st speed gear (1b), the 1st and the 2nd speed synchronizer rings (1c) and the ring nut (1d) on the second layshaft and fit them on the hydraulic press.

1. Fit the sleeve and three presynchronizer mountings (1a), the 1st and 2nd speed synchronizer rings (1b) and the retaining ring (1c).

1. Position the bearing (1a), the 2nd speed gear (1b), the two half rings (1c), the spacer (1d), the needle bearing (1e), the 5th speed gear (1f) and the 5th and 6th speed synchronizer assembly (1g) on the second layshaft and fit them on the hydraulic press.

1. Fit the retaining ring (1a), the needle bearing (1b) and the 6th speed gear (1c).

If the rear bearing is replaced, calculate the thickness of the calibrated retaining ring as described below. Calculate the difference in thickness between the new and the old rear bearing and add this difference to or subtract it from the thickness of the removed retaining ring. A retaining ring set is available from Parts.

1. Fit the rear bearing at the press.

1. Fit the rear bearing retaining ring.

PROCEED WITH REASSEMBLY OF THE LAYSHAFT (B) AS DESCRIBED BELOW.

If the thrust bearing is replaced, calculate the thickness of the new calibrated retaining ring as described below. Calculate the difference in thickness between the old and new thrust bearing. The value of the difference should be added to or subtracted from the thickness of the retaining ring removed to determine the thickness of the new retaining ring that should be fitted. A retaining ring kit is available as a spare.

1. On the press, use the tools (1a) and (1b) to fit the thrust bearing (1c).

2. Fit the retaining ring (2a), the needle bearing (2b), the reverse gear (2c) and the synchronizer ring (2d).

1. At the press, using tool (1a), fit the synchronizer sliding sleeve (1b).

1. At the press, using tool (1a), fit the spacer (1b).

1. Fit a new retaining ring (1a), three presynchronizer mountings (1b), the sliding sleeve for reverse gear (1c), the needle bearing (1d), the 3rd speed gear (1e) and three synchronizer rings (1f).

1. At the press, using tool (1a), fit the synchronizer ring nut (1b). Make sure that the teeth shown in the diagram are in the correct position.

1. Fit the synchronizer retaining ring.

1. Fit three presynchronizer mountings (1a) and sleeve (1b) complete with seals (1c).

1. Fit the needle bearing (1a) and the 4th speed gear (1b).

2. At the press, using tool (2a), fit the rear bearing (2b).

1. Fit a new retaining ring (1a) securing the rear bearing and position forks (1b) on layshaft (1c).

REASSEMBLE THE MAIN SHAFT (A) AS DESCRIBED BELOW.

1. At the press, using tools (1b) and (1c), fit the front bearing (1a).

1. At the press, using tools (1b) and (1c), fit the 3rd and 5th speed drive gear (1a).

1. Fit the spacer.

2. At the press, using tools (2b) and (2c), fit the 4th speed drive gear (2a).

1. At the press, using tools (1b) and (1c), fit the 6th speed drive gear (1a).

1. At the press, using tools (1b) and (1c), fit the rear bearing (1a).

REASSEMBLE THE CLUTCH CASING AS DESCRIBED BELOW.

1. Fit the main shaft front bearing outer race (1a) using tools (1b) and (1c).

1. Fit the layshaft front bearing outer races (1a) using tools (1b) and (1c).

1. Fit the bearing for gear selector and engagement shaft (1a) in its housing using tools (1b) and (1c).

- Fit the main shaft and the two layshafts complete with forks in their housings in the clutch casing.

DETERMINE THE SIZE OF THE THRUST RINGS AS DESCRIBED BELOW.

1. Tighten the main shaft rear bearing retaining screw to the prescribed torque using the special tool for counter-torque.

2. Fit the outer races on the gearbox shafts.

1. Tighten the rods with the spacers on the clutch casing.

2. Fit the three gauges on the three gearbox shafts.

3. Fit gearbox casing (3a) on the rods fitted previously and tighten the nuts (3b) to a torque of 25 Nm, starting with tightening the nuts near the locating bushes.

4. Rotate the main and layshafts through about twenty revolutions using the special tool.

5. Measure the gap between the two cylinders for each of the three shafts using a feeler gauge.

- Determine the size of the new thrust ring for the main shaft (A) by subtracting the maximum permitted clearance of 0.10 mm from the reading taken previously using the feeler gauge.

- Determine the size of the new thrust ring for the layshaft (B) by adding the maximum pre-loading of 0.20 mm to the reading taken previously using the feeler gauge.

- Determine the size of the new thrust ring for the second layshaft (C) by adding the maximum pre-loading of 0.30 mm to the reading taken previously using the feeler gauge.

- Remove the gearbox casing and all the components for the tool from the clutch casing.

1. Fit the gearbox casing (1b) on the tool (1c) using two nuts (1a) taking care to position the three studs (1d) by the three shaft housings.

1. Fit three new thrust rings (1a) and the outer races for main and layshaft rear bearings (1b) using tools (1c) and (1d).

- Apply LOCTITE 510 sealant to the entire matching surface between the gearbox casing and the clutch casing.

- Remove the gearbox casing from the support tool and fit it on the clutch casing tightening the screws to the prescribed torque.

1. Fit a new main shaft sealing ring on the clutch casing using the special fitting tool.

- Fit the gear selector and engagement assembly on the clutch casing, tightening the screws to the prescribed torque.

- Fit the clutch control coaxial actuator to the clutch casing tightening the screws to the prescribed torque.

- Connect the three-way connector to the oil pipe for the coaxial actuator and to the clutch casing.

- Undo the fastenings and remove the gearbox and differential from the support tool.

- Remove the support tool from the overhaul stand.