To Assemble

TO ASSEMBLE
1a Before fitting the reverse gearwheel to the output shaft, check the distance from the primary chaincase joint face down to the output shaft nut. The distance should be 195.0-195.1 mm (7.677-7.681 in). If the dimension is not within this range, fit shims between the nut and the reverse gearwheel. The shim thicknesses available are 0.30,0.40 and 0.50 mm (0.012, 0.016 and 0.109 in). If the position of the output shaft has not changed, the earlier shims may be refitted.





1b The shimming procedure is as follows:
- Fit tool 87 90 552 into the gearcase as shown in the figure, and use feeler gauges to measure the distance between the tool and nut.
- Fit shims corresponding to the thickness of the feeler gauges.





2. Use sleeve 83 90 148 to fit the reverse gearwheel.





3. Fit 1st gearwheel onto the reverse gear bearing sleeve.





4. Fit the 1st/2nd gear synchromesh hub. Fit the 1st/2nd selector fork to the 1st/2nd synchromesh sleeve, and fit the assembly onto the synchromesh hub.





5. Use tool 83 90 148 to fit the sleeve for 2nd gearwheel and fit 2nd gearwheel onto the sleeve.





6. Use tool 83 90 148 to fit the thrust washer and sleeve for 3rd gearwheel and fit 3rd gearwheel onto its sleeve.





7. Fit the 3rd/4th synchromesh hub. Fit the synchromesh hub with the three locking holes facing towards the nut. Fit the 3rd/4th selector fork to the 3rd/4th synchromesh sleeve and fit the assembly onto the synchromesh hub.





8. Fit tool 87 90 503 to lock the reverse gear-wheel, tighten the output shaft nut to a torque of 40-60 Nm (28-44 lb ft) and Lock the nut. Remove tool 87 90 503.





Tightening torque for output shaft nut: 40-60 Nm (28-44 lb ft)

9. Set the synchromesh sleeves on the output shaft to the neutral position and fit the shaft for 1st/2nd and 3rd/4th selector forks.





10. Turn the selector rod clockwise to enable the selector shaft for reverse gear to be fitted, and fit this shaft. Lock the shaft with the set screw. Lock the set screw with Loctite 242. Alternatively, hammer in the tubular dowel, but make sure not to hammer it in too far.
11. Fit the needle bearing into the layshaft pinion set. Then place the layshaft pinion set in the bottom of the gearcase.
12. Check that the thrust washer for the layshaft gearwheel is in the correct position in the primary chaincase. The washer can be glued in position to facilitate the fitting of the layshaft gearwheel. Also check that the connection tube is fitted to the primary drive output shaft.





13. Apply Loctite 510 sealing compound to the joint face of the primary chaincase and fit the chaincase to the gearcase.

NOTE: Tighten the bolts lightly. This will ensure that the loose pinion set will not jam in the wrong position before the layshaft is fitted.





14. Move the layshaft pinion set to the correct position either by turning the gearbox or by lifting the layshaft pinion set. Fit the rear thrust washer and insert the layshaft using tool 83 90 049.
15. Tighten the primary chaincase bolts.





16. Fit the reverse gearwheel and shaft. Make sure that the reverse lever enters the groove in the gearwheel. Fit the locking place for the reverse gear shaft and the layshaft. Lock the bolt with Loctite 242.

Tightening torque: 23-28 Nm (17-21 lb ft)





17. Fit the differential unit. Refer to Service and Repair at "Differential, Manual Transaxle". Service and Repair
18. Check the shaft seals in the differential bearing housings, and fit new seals if necessary.

Tightening torque: 23-28 Nm (17-21 lb ft)
Apply thread sealing compound to the threads.
Adjust the crown wheel backlash so that, if the bearings have been in service less than 10,000 km (6,000 miles) it will be 0.17 +/- 0.05 mm (0.07 +/- 0.002 in). Measure at four points.

Adjust as described, refer to "To Adjust the Pinion/Shimming" at Differential, Manual Transaxle/Adjustments. Adjustments

19. If the primary chain drive has been dismantled, re-assemble it.
20. Fit the spring for the selector rod. Check that the detent ball is in position.
21. Fit gaskets to the covers and fit the covers to the gearcase.
22. Fit the gearcase with oil (2.5 litres).

NOTE: When a dry gearbox is filled, the level will drop when the car is travelling since about 3 dl of oil will be transferred to the primary chaincase.