To Dismantle

(Proceed in the following order as far as necessary to remove the component that needs attention)
1. Wash the gearcase and drain the oil:
a) with the gearbox horizontal
b) with the gearbox vertical. Let the oil drain out of the primary chaincase.





2. Remove the following covers:
- Front cover on the primary chaincase
- Side cover on the primary chaincase (there will be some oil remaining in the primary chaincase).
- Side cover on the gearcase.
- Final drive cover.





3. Measure the backlash between the pinion and crown wheel. Refer to "To Adjust the Pinion" at Manual Transmission/Transaxle/Service and Repair. Service and Repair

IMPORTANT NOTE: Always measure the positions 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. Refer to "To Adjust the Pinion" at Manual Transmission/Transaxle/Service and Repair. Service and Repair





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 parts.





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 plunger from the 5th gear selector fork.
8. Move the reverse gear into the reverse position and engage 5th gear.









9. Use a drift to remove the peened-over material from the flange of the input shaft nut and remove the nut (bottom sprocket).





10. Remove the chain tensioner. Use a rubber band to keep the pads in.





11. Remove the circlip in front of the upper chain sprocket bearing.








12. Remove both sprockets and chains simultaneously. Sliding hammer 83 90 270 and sleeve 87 90 891 may be needed to remove the sprockets.








13. Move the layshaft drive gearwheel out of mesh by first removing the circlip and then moving the sleeve towards the gearwheel.











14. Remove the looking plate. Use a drift from the primary chaincase side to tap out the layshaft so that the layshaft drive gearwheel can be removed to the side, together with the sleeve and circlip.





15. Remove the bolts for the input shaft bearing housing, thus releasing the front oil catcher.





16. Then use sliding hammer 83 90 270 and adapter 87 90 917 to remove the bearing housing.





17. Swing out the 5th selector fork and remove the synchromesh sleeve.





18. Use tool 83 90 049 to remove the reverse gear shaft.





19. Remove the reverse gear by tilting out the left-hand end first.





20. Fit locking tool 87 90 503.





21. Release the nut or remove the circlip for the 5th gear synchromesh hub. Remove the hub and sleeve.





22. Remove tool 87 90 503.





23. Remove all primary chaincase bolts and tap in the tubular dowels so that the chaincase can be separated from the gearcase. Remove any burrs around the hole in the shaft for 5th speed selector fork so that the hole in the gearcase will not be damaged. The 5th gear selector fork can be removed when the chaincase is removed.





24. Remove the layshaft and the layshaft pinion set. Make sure that the bearing in the layshaft gearwheel remains in place.





25. Remove the 5th gear actuator.





26. Remove the shaft for the selectors and actuators. The actuator for reverse gear together with the shaft for 5th and reverse gear may be left in the gearcase.





27. Remove the four bolts for the output shaft bearing housing.





28. Fit tool 87 90 511 and press out the output shaft. Save the pinion sleeves, washers and shims.

WASHING
After removing the part that needs attention, remove any gasket remnants and sealing compound from the covers and joint faces. Inspect the gearcase and all dismantled parts and wash them in paraffin (kerosine) or the like. Then grease and oil the parts with the lubricants listed in the specification under LUBRICANTS.