2. With the gear mount on the bench, install the locking keys into their positions as shown in Fig. 2. 6.23. If the selector clips were removed, they can be installed later with a magnetic rod (photo).
3. Fold the 1/2 gear shift fork and the 1/2 gear synchronizer sleeve on the driven shaft, lower them simultaneously into the gear fastener housing.
4. Insert the reverse gear shaft, and at the same time position the reverse gear between the teeth of the transmission arm (photo). Insert the shaft completely.
5. Fold the 3/4 shift fork with the 3/4 gear synchronizer sleeve on the input shaft, lower them into the gear retainer and engage with the output shaft gears. Make sure that the synchronizer bushings are located centrally in the hubs, otherwise the lock crackers may pop out.
6. Insert the small lockout key into the 3/4 shift shaft, secure with grease. Insert the 3/4 shift rod into the gear retainer through the shift fork.
7. Align the holes, insert the roll pin into the end of the fork shank.
8. Supporting the front ends of the shafts, install the bearing inner race on the output shaft, insert it with a metal tube until it contacts the outer race (photo).
9. Position the 5th gear thrust washer on the input shaft, slide the 5th gear inner race (photo). The inner ring can be preheated to 120°C to facilitate installation.
10. Position the 5th driven gear on the output shaft, insert it fully into the grooves using a metal tube (photo). The gear can be preheated like the ring in step 9 to facilitate installation.
11. Position the 5th gear needle bearing on the input shaft, lubricate them with gear oil.
12. Fold 5th shift fork with 5th synchro sleeve/gear, place assembly over shift shaft to input shaft (photo).
13. Install the 5th gear synchronizer ring on the synchronizer (photo).
14. Install the coupling, put it completely on the grooves using a metal pipe (photo). The sleeve can be preheated to 120°C to facilitate installation.
15. Position the new gasket on the final drive housing (photo).
16. Wrap tape around the end of the input shaft (photo). Lower the fastener of the gears onto the final drive housing and insert the bolts with the mounting bracket.
17. Insert dowel pins, tighten bolts in diagonal sequence to torque specified in Specifications.
18. Engage 5th gear by moving the synchronizer sleeve (i.e. leaving the shift rod in the neutral position) and 1st gear by pushing the 1/2 shift shaft. The input and output shafts are now locked.
19. Tighten the output shaft nut to the torque specified in the Specifications (photo). After tightening the nut, return the mechanisms to the neutral position.
20. Align the holes, insert the roll pin into the 5th gear fork.
21. Position the 1/2 gear selector clamp on the shaft near the end position, but do not install the roll pin at this stage.
22. Extend the shift shaft to engage the 3rd gear, then insert the main shift shaft including the ends of the springs into the 3/4 shift shaft, and with your finger in the notch, push the main shift shaft into the bushing. After installation, push the 3/4 shift rod into neutral position (photo).
23. Align holes, insert roll pin into 1/2 gear selector clamp.
24. Place a new gasket on the fastener of the gears, lower the shift cover. If necessary, lightly tap the inner race of the ball bearing to position it at the end of the input shaft.
25. Insert the hanger bolts, lubricating the threads with sealant. Tighten the bolts in diagonal sequence.
26. Insert a bolt and thick spacer at the end of the input shaft, tighten to the torque specified in Specifications, using the method described in Chapter 13, point 7 (photo).
27. Clean the notch and insert a new cover plate (photo).
28. If the differential has not yet been installed, lower it into the final drive housing. Clean cover and mating surfaces of housing, apply sealant. Position the cover on the casing, insert and tighten the bolts in a diagonal sequence with the tightening torque indicated in Specifications. Note that the magnet on the cover must be placed at the bottom (photo).
29. Insert the drive flanges on each side of the differential, tighten the bolts (photo).
30. Install the clutch release bearing and shaft as described in Section 5.
31. Insert and clamp the reversing light switch, secure the electrical wiring.
32. Fill the gearbox with oil.
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