Page 71
18.Fit the shims which were previously
tested to the hub so that there is no
axial play once the circlip has been
fitted.
Fil locking tool 8790505 to the re-
verse gearwheel. Tighten the nut to a
torque of 50 + 10 Nm (5 + 1 kgfm; 37 +
7 Ibft).
Upset the flange of the nut in the
groove in the hub, using a drift with a
rounded nose,
19.Fit the synchro sleeve for 5th gear and
the gear shift fork.
20.Fit the input shaft together with the
bearing housing, oil catcher and con-
necting pipes. Use three guide pins
87 90 438 for alignment and the sproc-
ket as a spacer between the adapter
87 90 917 and bearing housing.
Insert the bearing housing far enough
for the shaft to meet the synchro
sleeve. The bearing housing should then
he driven into place using slide hammer
8390 270. Check the compression of
the bearing before installation. (See in-
put shaft and bearing housing, section
471).
21.Up to and including gearbox No.
437802, 1982 models: Fit the thrust
washer for the constant mesh gear an
the input layshaft. Grease the washer
and fit it with the tab located in the
special recess.
As from gearbox No. 437803, 1982 mo-
dels: A new bearing without a thrust
washer supersedes the earlier one.
22.Fit the roller bearings and = innner
bearing track in the constant mesh
gear.
471—32
Page 72
23.Fit the constant mesh gear complete
with sleeve, circlip and bearing rollers.
Slide the layshaft gear cluster back to
enable the gear to be fitted.
24.Slide the synchro sleeve onto the lay-
shaft and fit the circlip in the groove.
25. To fit the layshaft thrust washer, with-
draw the layshaft and slide the washer
into position. Then use tool 83 90 049 ta
insert the shaft so that it locks in
Position.
é
Thrust washer, up to and including gearbox
No. 437800
471-33
Page 73
a oy,
26.Fit the reverse gearwheel and shaft.
Make sure that the reverse lever
engages the groove in the reverse year.
Adjust the shaft using tool 8390 049
until it locks in position.
27.Fit the locking plate over the shaft
ends and seal the bolt with Loctite 242.
28.Fit the primary gear sprockets and
chains. Ensure that the hole for the tab
washer on the lower sprocket is facing
outwards,
29.Fit the chain tensioner. Apply locking
fluid to the bolts prior to installation.
30.F it the nut onto the input shaft. Before
torque tightening select reverse and 5th
speed gears at the same time so locking
the input shaft. Then tighten the nut to
the prescribed torque of 100 + 10Nm
and upset one of the nut tabs into the
recess provided in the gearwheel, using
4 round-nosed drift.
471-34
Page 74
31.F it the dowel in the gear selector fork
selector for 5th gear.
32.Fit the differential unit. See section
473.
33.Check the shaft seals in the bearing
retaining housings and replace _ if
necessary. Adjust the crownwheel
backlash if necessary. See section 473.
Then fit the two drive shafts and inner
universal joints. Ensure that the seals
are not damaged. Fit the selector ball
and spring and fit the gearbox top cover
assembly and gasket.
34.F it the final drive unit, cover and gas-
ket, the primary gear housing and the
chain cover with gaskets.
35.Refill with oil: 0.31 in the primary
drive and 2.7 1 in the gearbox.
1
471-35
Page 75
-
Pinion shaft, 5-speed transmission
Dismantling
To dismantle the pinion shaft, follow the
instructions for dismantling the transmis-
sion up to the point where the pinion shaft
assembly is removed. Then continue as
follows:
l. Secure fixture 87 90 636 and holder ring
87 90 651 ina vice. Put the pinion shaft
in the fixture and loosen the nut using
spanner 87 90 453,
From 1982 models, as from gearbox No.
436501, in which the final drive ratio is
9,33, use holder ring 87 91 097.
2. Mount the bearing assembly on sleeve
85 90 098, and press out the bearing
from its housing.
3. Press off the rear roller bearing with
the aid of tools 8790636 = and
87 90 651. From 1982 models, as from
gearbox No. 436501, in which the final
drive ratio is 9.33, use holder ring
87 91 097.
471~—36
Page 76
4, Press the outer rings of the taper roller
bearings out of the bearing housing
using tools 8390098, 8390106 and
83 90 148 (see illustration).
Fitting the pinion shaft
Having removed the part that needs atten-
tion, inspect all the dismantled parts and
wash them in kerosene or similar. Then
reassemble and fit, proceeding as follows:
Note
Lubricate the bearings before as-
sembly.
1. Press the outer races of the tape roller
bearings into Lhe bearing housing, using
tools 83 90 189 and 87 90 441.
Pinion shaft with bearing, bearing housing
and spacer sleeve,
471-37
Page 77
2. Press on the roller bearing adjacent to
Mew
the pinion until it butts against its stop,
using tool 87 90636 and fitting ring
87 90 925.
Fit the spacer sleeve on the shaft.
Fit the bearing housing.
Fit the front roller bearing.
Set up the shaft in 4 press (see illustra-
tion). Press the bearing housing slowly
on, using fixture 87 90 636 and fitting
ring 87 90 925. Rotate it at the same
time until resistance is felt.
Smear Loctite 270 on the threads and
put on the nut. Fit fixture 87 90 636
with holder ring 8791097 in a vice.
Place the bearing housing on the fix-
ture. Using spanner 87 90 453, tighten
the nut until the correct rolling torque
is abtained. To determine the rolling
torque, wind a line around the bearing
housing and attach the other end to a
spring balance. Lightly oil the bearings
and tighten to the following rolling
torque: New bearings 47-71 N (10-15 Ib,
4.7-7.0 kg) on the spring balance which
corresponds to a torque of 2.5 + 0.5 Nm
(1 + 0.5 Ibft, 25 + 5 kgfem). After the
correct value has been obtained, upset
the flange of the nut using a drift.
471—38
Page 78
-
8. Fit two locating pins, toal 87 90 438, in
the gearbox housing. Then fit on the
shims and fit the pinion shaft with
bearing housing. Knock the bearing
hausing carefully into place using a
plastic mallel or hammer together with
drift 83 90.114 and sleeve 84 90 148.
Apply Loctite to the four bolts and
then tighten them to a Lorque of 20-25
Nn (2.2-2.5 kgfm, 15-18.5 Ib ft).
Primary gear case
The primary gear case should be removed
when dismantling the gearbox. Separate
the primary gear case complete with the
following components from the gearbox: A.
Rall bearing, B. Needle bearing, C. Clutch
shaft seal, D. | evel control ball valve.
Dismanlle the parts as follows:
Dismantling
l. Remove the four countersunk sockel-
head cap screws and remove the ball
bearing retainer.
2. Drift out the ball bearing. Use drift
§3 90 104 and sleeve 83 90 148.
471-39
Page 79
3)
Remove the needle bearing sleeve in
the primary gear case by means of drift
83 91 997 and 83 90 577.
Do not remove the level control ball
valve. Just check that the ball moves
freely and sits securely on ils seat.
The ball valve acts at low speeds down-
hill to prevent the oil fram running out
of the gearbox and inte the primary
gear case, so ensuring proper lubrica-
tion of the differential and final drive
units.
Remove the clutch shaft sea] by means
of a screwdriver.
Fitting
1. Fit the ball bearing with the bearing
retainer. Seal the two through-screws
with thread sealant. Tighten dawn the
screws alternately until the bearing is
in position.
471—40
Page 80
2.
Fit the needle bearing race with the
numbered end pointing out towards Lhe
primary gear case. Use drift 83 91 997
ond sleeve 78 41 067.
Fit a new clutch shaft seal, using drift
8391997. Grease the lips of the seal
after it has been fitted. See Lubricant
Specification.
Primary drive
Dismantling
1,
To dismantle the primary drive sepa-
raLely, remove the front caver from the
primary drive case. Otherwise follow
the instructions under "Removal and
installation, manual transmission, 5-
speed".
Remove the circlip from the upper
sprocket.
471-41