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 0.019 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.
As from gearbox numbers 523814 and 480053, the cone angles of the synchromesh sleeve and baulk ring have been altered from 6.67° to 6°. The synchromesh sleeve with the altered cone angle has a turned step which is provided only for identification purposes. The step can face either towards the front or towards the rear.





1. Turned step (can face either towards the front or towards the rear)
2. Cone angle
3. Synchromesh sleeve
4. Baulk ring
5. Gearwheel
6. Symmetrical
7. Tip angle
8. Asymmetrical





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 gear synchromesh hub. Fit the 3rd/4th selector fork to the 3rd/4th synchromesh sleeve and fit these onto the synchromesh hub.
As from gearbox numbers 523814 and 480053, the cone angles of the synchromesh sleeve and baulk ring have been altered from 6.67° to 6°. The synchromesh sleeve with the altered cone angle has a turned step which is provided only for identification purposes. The step can face either towards the front or towards the rear.





1. Turned step (can face either towards the front or towards the rear)
2. Cone angle
3. Synchromesh sleeve
4. Baulk ring
5. Gearwheel
6. Symmetrical
7. Tip angle
8. Asymmetrical





8. Fit the sleeve for 4th gearwheel. Fit the gearwheel onto the sleeve. Fit the sleeve for the ball bearing.
9. If the selector rod has been removed, refit it together with the guide pin of the selector interlock device.





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





11. Fit the actuator for 5th gear to the reverse gear selector shaft.
12. Fit the needle bearing into the rear layshaft pinion set and fit the pinion set into the gearcase.





13. Fit the layshaft pinion set and the shaft and raise the pinion set to line it up with the shaft. Insert the shaft to hold the pinion set in position.





14. Fit the spacer sleeve, 5th hub and circlip onto the output shaft. Try suitable combinations of shims for the clearance between the hub and sleeve to take up any play between the parts on the output shaft. The available shim thicknesses are 0.30 mm and 0.40 mm. Then remove the circlip, hub and spacer sleeve. As from the 1982 model, the circlip and shims have been replaced by a nut.





15. Tap in the tubular dowels and apply Loctite 510 to the primary chaincase joint face. Fit the chaincase to the gearcase.
As from the 1986 model:
Make sure that the locating dowel fits between the ends of the spring on the selector rod. Remember that the 5th gear selector fork must be fitted now. Tighten the bolts.
Tightening torque: 23-28 Nm (17-21 lb ft)





Fit the spacer sleeve to the output shaft. Fit the 5th gear synchromesh hub.





16. Fit locking tool 87 90 503 to the reverse gearwheel.
17. Up to and incl. the 1982 model, gearbox No. 436500: Fit shims of the thickness measured earlier, so that all play will be taken up when the circlip is fitted.





18. Tighten the nut.
Tightening torque: 50 +/- 10 Nm (37 +/- 7 lb ft)





Lock the nut by peening over its flange into the holes in the hub. Use a drift with a rounded nose. Remove locking tool 87 90 503.





19. Fit the 5th gear synchromesh sleeve into the selector fork.





20. Fit the input shaft together with the bearing housing, oil catcher and connecting pipe. Use two guide pins 87 90 438 for alignment. Push in the bearing housing so that the shaft comes into engagement with the sleeve. Use the bolts to press in the bearing housing.
Tighten the bolts.
Tightening torque: 23-28 Nm (17-21 lb ft)

NOTE: Before fitting, check the bearing preload (refer to "To Diamantle").





21. Up to and incl. gearbox No. 437802, 1982 model: Fit the thrust washer for the front layshaft gearwheel. Grease the washer and fit its guide tab into the recess provided for this purpose.
As from gearbox No. 437803, 1982 model: New front bearing without thrust washer.
Thrust washer up to and inci. gearbox No. 437802





22. Fit the rollers and the inner bearing race into the front layshaft gearwheel.





23. Fit the layshaft drive gearwheel complete with sleeve, circlip and bearing rollers. Insert the shaft for the layshaft all the way in.





24. Slide the sleeve over and fit the circlip into the groove.
25. Withdraw the shaft of the layshaft pinion set and fit the thrust washer into place. Then use a drift to push the shaft of the layshaft pinion set into the locking position. If necessary, use tool 83 90 049 to turn the shaft.









26. Fit the reverse gear and shaft. Make sure that the pivoted segment of the reverse gear lever engages into the groove in the reverse gear. Use tool 83 90 049 to adjust the shaft to the proper locking position.





27. Apply Loctite 242 to the locking plate bolt.
Tightening torque: 23-28 Nm (17-21 lb ft).
Fit the locking plate to secure the shafts.





28. Fit the primary drive chains and sprockets. Check that the locking holes of the bottom sprocket face out towards the nut side.





29. Fit the chain tensioner. Apply Loctite 45 to the mounting bolts and tighten the bolts.
Tightening torque: 23-28 Nm (17-21 lb ft)





30. Fit the nut to the input shaft. Before tightening, engage reverse gear and 5th gear simultaneously to lock the input shaft.





31. Then tighten the nut.
Tightening torque: 100 +/- 10 Nm (74 +/- 7.4 lb ft)





32. Peen the nut flange into the holes. Use a drift with a rounded nose.
33. Fit the locking pin into the actuator of 5th selector fork. Test the gear positions.





34. Fit the differential unit. Refer to Service and Repair at "Differential, Manual Transaxle". Service and Repair
35. 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 (0.007 +/- 0.002 in). Measure at four points.
If necessary, adjust as described at "To Adjust the Pinion/Shimming" at Differential, Manual Transaxle/Adjustments. Adjustments





36. Fit the covers and gaskets for the final drive unit, primary chaincase and gearcase side cover. Fit the speedometer drive.
37. Pour 0.3 litres of oil into the primary chaincase and 2.7 litres into the gearcase.