1. Fit the gearbox with differential (1a) on the overhaul stand (1b) using the support (1c).

Two operators are needed for this operation.

1. Use tools (1a), (1b) and (1c), to remove the differential left inner driveshaft (1d).

1. Release the clutch thrust control bearing and remove it.

- Remove the outer clutch thrust control linkage retaining ring.

- Remove the outer clutch thrust control linkage.

1. Remove the outer clutch thrust control bushing.

1. Remove inner clutch thrust control linkage (1a) and the relevant inner bush (1b).

1. Undo the screws (1a) and remove the seal for the gearbox input shaft (1b) from the manual gearbox bellhousing.

1. Undo the screws (1a) and remove the gear selection/engagement device mounting bracket (1b).

1. Undo the screws (1a) and remove the manual gearbox rear cover (1b).

- Engage any gear using the gear selection/engagement lever.

1. Undo the screw (1a) fixing the 5th speed drive fork (1b).

- Engage the 5th speed by pressing the fork on the main shaft.

If two gears are engaged simultaneously the gear shafts will lock.

1. Use a suitable drift to straighten the staking on the main and layshaft ring nuts.

1. Undo and remove the ring nuts for the main and layshafts.

1. Remove the 5th speed drive fork along with the 5th speed sliding sleeve.

2. Remove the retaining flange for the pre-synchronizer mountings.

3. Remove the pre-synchronizer mountings.

4. Remove the 5th speed engagement sliding sleeve hub.

5. Remove the 5th speed pre-synchronizer ring.

6. Remove the 5th speed drive gear.

7. Remove the needle bearing for the 5th speed drive gear.

8. Remove the 5th speed driven gear.

1. Position the 5th speed sliding sleeve in a vice with protective jaws.

2. Apply a brass punch on the two ends (2a) of the fork (2b) alternatively, until they are released from the 5th speed sliding sleeve.

Take care not to nick the tapered part of the sleeve and the ends of the fork with the drift.

1. Use a universal extractor to remove the 5th speed drive gear bush.

1. Remove the spacer.

1. Undo the screws (1a) and remove the main and layshaft rear bearing retaining plate (1b).

1. Remove the main and layshaft rear bearing retaining rings

To remove the retaining rings, arrange them with their openings at the front.

1. Undo the reversing light switch and remove it.

2. Undo the reverse idler gear shaft fixing screw.

1. Undo the screws (1a) and remove the left flange on the differential (1b) with included oil seal and gasket (1c).

2. Remove the differential bearing preload thrust ring.

- Operate the gear selector/engagement lever and put the gearbox in neutral.

1. Undo the plug (1a) and fit a suitable pin (1c) in the relevant hole (1b) until the gear engagement fork control rods are locked in neutral.

1. Unscrew the gear selector lever inner support locking pin.

1. Undo the inner screws securing the manual gearbox bellhousing and the gearbox casing.

1. Undo the screws (1a) and remove the gearbox casing (1b) from the manual gearbox bellhousing.

1. Undo the screws (1a) and remove the mounting with reverse engagement fork lever (1b).

1. Remove the pin used for locking the gear engagement fork control rods.

2. Undo the screw (2a), extract the rod (2b) and remove it with the 1st-2nd speed drive fork (2c).

1. Undo the 3rd-4th speed fork fixing screw from the relevant rod.

2. Extract the 3rd-4th speed drive rod (2a) and the 5th-reverse speed drive rod (2b) simultaneously, then remove them along with the 3rd-4th speed fork (2c).

1. Remove the main shaft (1a) and the layshaft (1b) assemblies simultaneously.

1. Remove the reverse idler gear shaft fixing screw support.

2. Remove the reverse idler gear.

1. Remove the reverse idler gear shaft complete with centring pin.

2. Remove the locating bush.

1. Remove the differential assembly.

1. Remove the magnet.

1. Remove the layshaft front bearing.

1. Remove the outer race (1a) for the right side differential bearing from the manual gearbox bellhousing, using tools (1b) and (1c).

1. Remove the engine side oil seal ring for the manual gearbox bellhousing.

- Position the gearbox casing in a vice equipped with protective jaws.

1. Undo the screws (1a) fixing the gear selector/engagement lever (1b).

1. Turn the gear selector/engagement lever to access the dog fixing pin.

2. Keep the gear selector/engagement lever pressed and use a suitable punch (2a) to remove the dog fixing pin (2b).

1. Take out and remove the gear selector/engagement lever.

2. Remove the gear selector/engagement rod inner mounting bracket (2a) and the dog (2b).

1. Undo the screws (1a) and remove the gear control drive plate (1b).

1. Use a suitable commercial tool to remove the left side differential bearing outer race from the gearbox casing.

DISASSEMBLE THE LAYSHAFT OPERATING AS DESCRIBED BELOW

1. On the hydraulic press using the tool (1a), remove the rear bearing (1b) and the 4th speed driven gear (1c).

1. Remove the spacer between the 3rd and 4th speed.

1. On the hydraulic press using the tool (1a), remove the 3th speed driven gear (1b) and the 2nd speed driven gear (1c).

- Position the layshaft in a vice fitted with protective jaws.

1. Remove the needle bearing for the 2nd speed driven gear.

2. Remove the 2nd speed synchronizer ring assembly.

1. Remove the 1st-2nd and reverse engagement sliding sleeve.

2. Remove the pre-synchronizer mountings.

3. Remove the 1st-2nd and reverse sliding sleeve hub retaining ring.

When refitting, replace the retaining circlip.

1. On the hydraulic press, use the tool (1a) to remove the 1st-2nd and reverse sliding engagement sleeve hub (1b), the 1st speed synchronizer ring assembly (1c) and the 1st speed driven gear (1d).

1. Remove the needle bearing for the 1st speed driven gear.

DISASSEMBLE THE MAIN SHAFT OPERATING AS DESCRIBED BELOW

1. On the hydraulic press using the tool (1a), remove the rear bearing (1b), the spacer (1c) and the 4th speed drive gear (1d).

- Position the main shaft in a vice fitted with protective jaws.

1. Remove the needle bearing for the 4th speed drive gear (1a), the 4th speed synchronizer ring (1b) and the 3rd-4th speed sliding sleeve (1c).

1. Remove the pre-synchronizer mountings for the 3rd-4th speed sliding hub.

1. On the hydraulic press, use the tool (1a) to remove the 4th speed drive gear bushing (1b), the 3rd-4th speed sliding sleeve hub (1c) the 3rd speed synchronizer ring (1d) and the 3rd speed drive gear (1e).

1. Remove the needle bearing for the 3rd speed drive gear.

Removing

- Proceed with washing and checking the condition of all the components.

REASSEMBLE THE MAIN SHAFT OPERATING AS DESCRIBED BELOW

1. Fit the needle bearing for the 3rd speed drive gear.

1. Fit the 3rd speed drive gear (1a), the 3rd speed synchronizer ring (1b), the 3rd-4th speed sliding sleeve hub (1c), the pre-synchronizer mountings (1d), the 3rd-4th sliding sleeve (1e) and the 4th speed synchroniser ring (1f).

2. On the hydraulic press using the tool (2a), fit the bushing for the 4th speed drive gear (2b).

1. Fit the needle bearing for the 4th speed drive gear.

1. Fit the 4th speed drive gear (1a) and the shim (1b).

2. On the hydraulic press, using tools (2a) and (2b) fit the rear bearing (2c).

REASSEMBLE THE LAYSHAFT OPERATING AS DESCRIBED BELOW

1. Fit the needle bearing for the 1st speed driven gear.

1. Fit the 1st speed driven gear (1a) and 1st speed synchronizer ring assembly (1b).

2. On the hydraulic press, using tool (2a) fit the 1st-2nd and reverse sliding sleeve hub (2b).

- Position the layshaft in a vice fitted with protective jaws.

1. Fit a new 1st-2nd and reverse sliding sleeve hub retaining ring.

2. Fit the pre-synchronizer mountings in their housings in the 1st-2nd and reverse sliding sleeve hub.

3. Fit the 1st-2nd and reverse engagement sliding sleeve.

1. Fit the 2nd speed synchronizer rings assembly.

2. Fit the needle bearing for the 2nd speed driven gear.

1. Fit the 2nd speed driven gear.

2. On the hydraulic press using the tool (2a), fit the 3rd speed driven gear (2b).

1. Fit the spacer between the 3rd and 4th speed.

1. On the hydraulic press using the tool (1a), fit the 4th speed driven gear (1b).

1. On the hydraulic press using the tool (1a), fit the rear bearing (1b).

- Position the gearbox casing in a vice equipped with protective jaws.

1. Place the gear control drive plate (1a) in its housing and tighten the screws (1b).

1. Place the gear selector/engagement lever (1a) in its housing along with the gear selector/engagement rod inner mounting bracket (1b) and the dog (1c).

1. Use a suitable punch to fit the new pin (1a) securing the dog (1b) to the gear selector/engagement lever (1c).

1. Tighten the gear selector/engagement lever (1b) fixing screws (1a) to the prescribed torque.

1. Fit a new engine side oil seal ring (1a) on the manual gearbox bellhousing using the tool (1b).

1. Fit the outer race (1a) for the right side differential bearing on the gearbox bellhousing, using tools (1b) and (1c).

1. Place the layshaft front bearing in its housing.

1. Place the magnet back in its housing.

1. Place the differential assembly back in its housing.

1. Fit the bushing for the reverse idler gear shaft.

Position the groove (a) of the bushing next to the rib, as shown in the figure.

2. Fit the reverse idler gear shaft (2a) by placing the pin (2b) in its housing on the bushing.

1. Fit the reverse idler gear.

Make sure that the gear engagement teeth are facing downwards.

2. Fit the reverse idler gear shaft fixing screw support.

1. Fit the main shaft (1a) and the layshaft (1b) assemblies simultaneously.

1. Fit the 5th-reverse rod (1a) and the 3rd-4th speed control rod (1b) complete with fork (1c) simultaneously.

2. Tighten the screw for the 3rd-4th speed fork to the prescribed torque.

1. Fit the 1st-2nd speed control rod (1a) complete with fork (1b).

2. Tighten the screw for the 1st-2nd speed fork to the prescribed torque.

1. Fit the mounting with reverse engagement fork lever (1a) and tighten the screws (1b) to the prescribed torque.

1. Position all the gear control forks in neutral and fit the suitable locking pin (1a) of the relevant rods (1b).

- Apply sealant to the contact surfaces between the manual gearbox bellhousing and the gearbox casing.

1. Fit the gearbox casing (1a) on the manual gearbox bellhousing and tighten the gear selector/engagement lever inner support locking pin (1b).

2. Tighten the screws fixing the gearbox casing to the manual gearbox bellhousing to the prescribed torque.

3. Remove the gear engagement fork control rod locking pin and tighten the relevant cap.

1. Tighten the inner screws fixing the manual gearbox bellhousing to the manual gearbox casing to the prescribed torque.

1. Tighten the reverse idler gear shaft screw to the prescribed torque.

2. Fit the reversing light switch.

1. Fit the main and layshaft rear bearing circlips.

Position the retaining rings with their openings at the front to facilitate fitting.

1. Fit main and layshaft rear bearing retaining plate (1a) and secure it by tightening screws (1b) to the prescribed torque.

1. Fit the spacer.

2. Fit the bush for 5th speed drive gear (2a) using the tool (2b).

1. Position the 5th speed sliding sleeve in a vice with protective jaws.

2. Position the fork so that the tapered part is in the same direction as that of the sleeve, resting it against the shoulder on the side where the sleeve diameter is smaller;

- fit the fork manually, exerting the necessary pressure, until it is completely inserted in the sleeve.

When the fitting is complete, check that the sleeve can rotate freely inside the fork.

1. Fit the 5th speed driven gear.

2. Fit the needle bearing for the 5th speed drive gear.

3. Fit the 5th speed drive gear.

4. Fit the 5th speed synchronizer ring.

5. Fit the 5th speed engagement sliding sleeve hub.

6. Fit the pre-synchronizer mountings.

7. Fit the retaining flange for the pre-synchronizer mountings.

8. Fit the 5th speed sliding sleeve complete with drive fork.

- Engage any gear using the gear selection/engagement lever.

- Engage 5th speed by pressing the main shaft drive fork.

If two gears are engaged simultaneously the gear shafts will lock.

1. Tighten the new ring nuts for the main and layshafts to the prescribed torque.

2. Stake the main and layshaft ring nuts using the tools (2a) and (2b).

- Place the 5th speed control fork in neutral.

1. Tighten the screw for the 5th speed control fork to the prescribed torque.

- Apply the prescribed sealant to the contact surfaces between the gearbox casing and the manual gearbox rear cover.

1. Fit the rear cover (1a) and secure it by tightening the screws (1b) to the prescribed torque.

1. Fit the left differential bearing outer race (1a) using tools (1b) and (1c).

1. Fit the mounting bracket (1a) supporting the gear selection/engagement device and tighten the screws (1b).

- Apply sealant to the contact surfaces between the gearbox inlet shaft gasket and the manual gearbox bellhousing.

1. Fit the gearbox input shaft gasket (1a) and tighten the screws (1b).

1. Place the inner bushing (1a) and the clutch thrust bearing control linkage (1b) in their housings.

1. Place the outer bushing of the clutch thrust bearing linkage in its housing.

- Fit the outer lever of the clutch thrust bearing control and the retaining circlip.

1. Fit the clutch thrust bearing and engage the control lever arm.

1. Fit the tool (1a) complete with dial gauge on the differential seal cover support surface, then bring the feeler gauge (1b) into contact with the taper roller bearing outer race (1c).

- Zero the dial gauge with a preload of 1 mm.

1. Position the tool (1a) complete with dial gauge on the differential sealing cover then bring the feeler gauge (1b) in contact with the surface (1c) and measure the difference.

- Calculate the size of the thrust ring for differential bearing pre-loading by adding 0.08 mm to the difference measured.

0.08 mm corresponds to the prescribed interference for the bedding-in and pre-loading of the differential bearings.

1. Place the thrust ring having the same size or the next largest size to the one calculated for the differential bearing pre-loading in the housing.

2. Fit the new sealing cover with included oil seal (2a) and the gasket (2b), then tighten the screws (2c) to the prescribed torque.

The cover with included oil seal and the gasket must always be replaced.

- Fit the differential inner driveshaft.

- Undo the fastenings and remove the gearbox together with the differential from the support tools.

Two operators are needed for this operation.