Disassembly
1. Install the gearbox on the stand (Fig. 8.16).
2. Drain the oil from the gearbox.
3. Remove lever A together with clutch release bearing B (Fig. 8.17). Remove guide sleeve C.
4. Remove the flanges of both axle shafts.
5. Unscrew the gearbox cover mounting bolts and remove it together with the oil seal (Fig. 8.18).
6. Engage fifth gear (arrows 1 and 2) (Fig. 8.19).
7. Loosen the nut (arrow A) on the fifth gear fork (Fig. 8.20). Unscrew the bolt (arrow B) and remove the fifth gear fork together with the 5th gear synchronizer sleeve.
8. Install the synchronizer sleeve back onto the synchronizer hub.
9. Loosen bolt A of 5th gear gear, engaging 5th gear (arrow 1) and 2nd gear (arrows 2 and 3) (Fig. 8.21). After engaging these two gears, both gearbox shafts are locked. Remove the 5th gear synchronizer hub and disengage 2nd gear.
10. Remove the retaining ring (arrow) from the synchronizer hub (Fig. 8.22).
11. Remove the synchronizer hub together with the 5th gear using puller A (Fig. 8.23).
12. Remove the needle bearing (arrow) (Fig. 8.24).
13. Remove the needle bearing bush (Fig. 8.25). Heat the needle bearing bush to approximately 100°C and remove it using puller A and tool 40-204.
14. Remove the 5th gear using puller A (Kukko 20/10) and bolt B (Fig. 8.26).
15. Compress the retaining ring (arrow) and remove it (Fig. 8.27). Unscrew the clutch housing mounting bolts.
16. Remove the clutch housing.
17. Remove the differential housing.
18. Remove the sealing plugs (Fig. 8.28).
19. Remove the gear shift rod, if necessary, use a punch (Fig. 8.29).
20. Remove the spring between pin A and console B (Fig. 8.30). Remove pin A.
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21. Unscrew the bolt (arrow) and remove the console together with the bushing (Fig. 8.31).
22. Unscrew the reversing light switch 1 and bolts 2, 3, 4 securing the reverse gear pinion (Fig. 8.32).
23. Remove rod 1 for engaging 5th gear and rod 2 for engaging reverse gear with lever 3 (Fig. 8.33).
24. Remove shaft 1 of reverse gear (Fig. 8.34). Remove input shaft 5, output shaft 4, rod 3 for engaging 1st and 2nd gears, rod 6 for engaging 3rd and 4th gears, gear 2 and shaft 1 from the gearbox housing.
Installation
25. Install output shaft 3 with rod 4 for engaging 1st and 2nd gears (Fig. 8.35). Install reverse gear pinion 1 on shaft 2 and install the shaft in the gearbox housing.
26. Raise the reverse gear pinion so that the reverse gear engagement lever can be inserted later (Fig. 8.36).
27. Raise the output shaft 1 with the rod for engaging 1st and 2nd gears and install the input shaft 3 with the rod 4 for engaging 3rd and 4th gears (Fig. 8.37).
28. Secure the shaft for the reverse gear pinion (arrow) (Fig. 8.38).
29. Insert reverse gear lever 1 into reverse gear engagement rod 2 (Fig. 8.39). Install them as a set, but first insert the lever into the reverse gear pinion.
30. Secure the reverse gear lever (arrow) (Fig. 8.40).
31. Install fork 1 for engaging 5th gear and secure it (Fig. 8.41).
32. Set the rods A to the neutral position (Fig. 8.42). Install the console B with the sleeve and tighten the bolt (arrow). Align the console B by inserting the shaft C and tighten the bolt (arrow). Remove the shaft C again.
33. Insert finger 1 into console 2 (Fig. 8.43).
34. Insert spring (arrow) between pin 1 and console 2 (Fig. 8.44). Insert shaft 3 into pin 1 and console 2. Insert plug 4.
35. Attach the differential.
36. Install the gearbox housing.
37. Install the reversing light switch.
38. Install the springs, thrust washers, cone rings and axle shaft flanges. There is a difference in diameter between the axle shaft flanges (Fig. 8.45).
Difference in diameter between axle flanges
| Designation | Axle shaft flange | Distance "a" |
| 1 | Left flange, gearbox side | 57 mm |
| 2 | Right flange, clutch side | 48 mm |
39. Further installation is carried out in the reverse order of removal.
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