To Dismantle

(PROCEED IN THE FOLLOWING ORDER AS FAR AS NECESSARY TO REMOVE THE COMPONENT THAT NEEDS ATTENTION)
1. Clean the gearcase and drain the oil.
2. Remove the final drive cover and the side cover.
Measure the backlash in the differential:





3. Fit a dial indicator into one of the holes for the cover bolts (final drive cover). Measure the backlash and note the value~

IMPORTANT NOTE: Always measure the position of the pinion and crown wheel before dismantling the gearbox, to check whether their locations are correct. If the pinion and crown wheel assembly has been in service for a relatively short distance (less than 10,000 km or 6,000 miles), re-adjustment may be carried out. But if it has been in service for a longer distance and the gears have become worn-in, their settings during re-assembly should be the same as those measured before dismantling.





4. Remove the speedometer drive from the left-hand bearing housing. Remove the bearing housings on both sides.





Use sliding hammer 83 90 270 and tool 83 90 776.
Save the spring and plunger at the shaft end of each universal joint driver, and save the shims which can be re-fitted if the differential backlash has not been altered by the replacement of some pants.





5. Remove the differential assembly. For dismantling instructions for the differential assembly, refer to Service and Repair at Differential, Manual Transaxle. Service and Repair





6. Measure the pinion distance and note the reading.








7. Remove the locking plate for the layshaft and reverse gear shaft. Use tool 83 90 049 to withdraw the layshaft so that the layshaft pinion set will drop down.
8. Separate the gearcase at the joint between the primary chaincase and the gearcase and remove the primary chaincase. The chaincase may have to be removed to one side.





9. Remove the layshaft pinion set (see figure).





10. Release the set screw for the reverse gear actuator shaft or remove the tubular dowel.
11. Turn the selector rod so that the actuator is released from the reverse gear selector and withdraw the shaft.





12. Remove the shaft for 1st/2nd and 3rd/4th selector forks, and remove the selector fork and synchromesh sleeve for 3rd/4th gears.

NOTE: The reverse gear lever need not be removed from the selector fork shaft when the shaft is removed.

13. Withdraw the reverse gear shaft. Use tool 83 90 049 and remove the reverse gear.





14. Remove the needle bearing for the output shaft, fit tool 87 90 503 to lock the reverse gear (see figure) and use a drift to release the peened-over material of the nut. Remove the output shaft nut.





15. Remove tool 87 90 503 and remove the 3rd/4th synchromesh hub and 3rd gear.





16. Remove the four bolts retaining the output shaft bearing housing. Fit tool 87 90 511 and press out the output shaft. Place the gears, sleeves, washers and shims in a safe place.

WASHING
After removing the part that needs attention, remove any gasket remnants and sealing compound from the covers and joint faces. Inspect all dismantled parts and the gearcase, and wash them in paraffin (kerosene) or the like. Then begin assembly as described below: