Lubricate all parts before assembly.
Note:
- This gearbox does not use a gasket between the clutch and gearbox, but uses a liquid sealant.
- Always clean the magnet (pos. 66) when disassembling the gearbox.
- Check all bearings for wear and smooth operation.
Torque
- A - 15 Nm (1,5 kgf-m.11lbf-ft)
- B - 27 Nm (2,8 kgf-m. 20lbf-ft)
- C - 31 Nm (3-2 kgf-m. 23lbf-ft)
1. Ball bearing.
2. Fifth gear synchronizer hub.
3. Fifth gear synchronizer clutch.
4. Fifth gear synchronizer spring.
5. Fifth gear synchronizer retaining ring.
6. Fifth gear gear.
7. Needle bearing 32x37x23.5.
8. Inner race of 4th and 5th gear gear bearings.
9. Needle bearing 34x39x23.
10. Fourth gear gear.
11. Synchronizer retaining ring.
12. Synchronizer spring,
13. 3rd/4th gear synchronizer clutch.
14. 3rd/4th gear synchronizer hub.
15. Third gear gear.
16. Needle bearing 34x39x27.5.
17. Primary shaft.
18. Puck.
19. Spring washer.
20. Ball bearing.
21. Oil seal.
22. Cork 28mm.
23. Spring
24. Gear selector shaft.
25. Clutch housing.
26. Lock guide bolt (39 Nm).
27. Reverse gear lock.
28. Reverse gear intermediate gear.
29. Reverse intermediate gear shaft.
30. Spring pin (replace).
31. 3rd and 4th gear shift head.
32. 5th gear and reverse shift knob.
33. MBS switch head.
34. 1st and 2nd gear shift fork.
35, 3rd and 4th gear shift fork.
36. 5th gear and reverse fork.
37. Retaining ring 52 mm.
38. Axial pressure adjusting shim. 65 mm (*1).
Axial pressure adjusting shim.70 mm (*2).
39. Oil guide plate.
40. Puck.
41. Reversing light switch.
42. Set screw.
43. Puck.
44. Spring 31.6 mm.
45. Steel ball.
46. Reverse light switch harness stand.
47. Gearbox bracket.
48. Sealing bolt 32 mm 25 Nm.
49. Oil seal
50. Drain plug 39 Nm.
51. Puck.
52. Oil filler plug.
53. Puck.
54. Gearbox housing.
55. Exhaust pipe stand.
56. Oil chute.
57. Reverse gear locking cam.
58. Reverse gear selection spring.
59. Reverse gear lock.
60. Gear selector C.
61. Gear selector B.
62. Castle.
63. Bushing.
64. Gear selector A.
65. Spring washer.
66. Magnet.
67. Ball spring installation bolt 22 Nm.
68. Locating pin 14x20 mm.
69. Axial pressure adjusting washer 72 mm. Axial pressure adjusting washer 80 mm.
70. Differential assembly.
71. Oil seal 14x25x17.5 mm.
72. Oil seal 35хх56х8 mm.
73. Gear shift rod.
74. Case.
75. Oil guide plate.
76. Needle bearing (*1) 30x47x21 mm. Needle bearing (*2) 30x55x21 mm.
77. Intermediate shaft.
78. Needle bearing 36x41x25.5 mm.
79. First gear gear.
80. Friction absorber.
81. Synchronizer ring.
82. Synchronizer spring.
83. Synchronizer hub for 1st and 2nd gears.
84. Reverse gear.
85. Synchronizer spring.
86. Synchronizer ring.
87. Friction absorber.
88. Inner race of the bearing.
89. Needle bearing 39x44x27 mm.
90. 2nd gear gear.
91. 3rd gear gear.
92. 4th gear gear.
93. 5th gear gear.
94. Ball bearing (*1) Needle bearing (*2).
95. Ball bearing.
96. Spring washer.
97. Lock nut 108-0-108 Nm.
*1: engines D14A3, D14A4, D15Z4, D15Z5, D16Y7;
*2: engines D15Z6, D15Z7, D16Y5, D16Y8, D16Y9,