It is a long time allready since I’ve done this job. But after 22932 hits up to 25-12-20 to this page you deserve more than the text: Yep it is also reasembled again.

So I have to dig into my memory how I did it.

At the end of this article are several diagrams how the transmission is assembled.

Put on a new O ring onto the reverse shaft. Try to hammer it into the housing without damaging the ring. Grease it before tapping it back into the housing.

01_tap_out_reverse

I’ve used this tool to put back the locking balls of the gear selection system. By this system you cannot select f.i. gear 1 and 3 silultaneously.

If one gear is engaged, it will mechanicall block the movement of the other one.

02_ball_retainer_tool

The gears are lubricated a bit to make them slide easier. It is also used to keep the keys in place.

03_1st_gear

04_shift_assy

05_shift_assy

06_shift_assy_key

07_synchro_ring

08_4th_shifter

09_4th_shifter

10_2nd_gear_synchro

11_2nd_1st_assy

Below is the new thrust washer and the old one

12_thrust_washers

13_2nd_1st_thrust

The new bearing is installed using the hydraulic press. The retaining clip snags in place when done right.

14_bearing_assembled

Insert the main shaft and place the lock ring.

15_bearing_ring_clip

Place the previous assembly onto the shaft.

16_2nd_gear

17_2nd_synchro

18_shifter_3-4

19_shifter_assy

20_shifter_toothing

21_mainshaft_assembled

22_bearing_ring

23_4th_gear_needles

24_countergear

25_countergear

26_needles_inserted

27_shimm_placement

28_countergear_installation

29_woodruff_key

30_result_countergear

31_reverse_washer_and_gear

32_reverse_gear

33_reverse_gear_bearing

34_iside_reverse_gear_placed

35_gasket_selection

36_mainshaft_completed

37_mainshaft_installed

To put on the subborn bearing, the press is used again.

38_clutch_side_bearing

To protect the bearing I used a tube and 2 plates. to spread the pressure in the inner and outer bearing ring.

39_clutch_side_bearing

40_bearing_installed

The snapring is now slush with the housing.

41_cover_plate

The bearing cover fits only one way.there is a square area, which must be positioned onto the oil return hole of the housing

42_rear_end_bearing

43_rear_end_seal

44_washer_extension_housing

45_reverse_gear

46_odometer_gear_gasket

47_extension_housing_assembled

48_seal_side_cover

49_shifterforks

50_shift_locking

51_complete_transmission

51_shift_locking

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