2. Clamp the rear crankcase in a vise, heat the housing around the bearing seat to approximately 100°C.
3. Lower the gearbox into the housing, making sure that the pinion shaft bearing is fully engaged (photo).
4. Place the retaining ring in the groove, remove the piece of wire.
5. Push the output flange onto the grooves of the secondary shaft, screw on the nut. Fix the flange and tighten the nut with the tightening torque specified specification (photo).
6. Place needle bearings in reverse idle gear, place gear on housing, insert shaft. Note that the identification groove on the mechanism must be facing forward (photo).
7. Insert and tighten the intermediate bolt. reverse shaft.
8. Lubricate the two locking pins and insert them between the holes in the driver bolster (photo).
9. Insert the 5/3X shift fork into the groove in the 5/3X synchronizer sleeve (photo).
10. Check that all synchronizer sleeves are in the neutral position.
11. Insert the 1/2 gear shift fork into the groove in the 1/2 gear synchronizer sleeve. Insert the 1/2 gear driver pin through the yoke into the rear crankcase, then place the selector clamp on the shaft (photo).
12. Insert the 3/4 shift fork into the groove in the 3/4 gear synchroniser sleeve. Insert the 3/4 gear pin through the yoke into the rear crankcase and turn until the otoorshik pins line up (photo).
13. Lubricate the four rollers and place them on the pins on the shift lever shaft (photo).
14. Insert the shift lever shaft with the selector pin into the rocker arm. Use a screwdriver to turn the rocker as needed to help the shaft slide in and get the selector finger into the switches (photo).
15. Insert the 5/3X drive shaft through the 5/3X shift fork into the rear crankcase (photo).
16. Align the holes on each driver roller, drive in the roll pins until they protrude approximately 1.0 mm outward (photo).
17. Insert detent balls and springs into rear crankcase.
18. Apply sealant to retainer plate (photo), then install it on the springs, insert the bolts and tighten them with the tightening torque regulated by the Specification.
19. Engage 4th gear and check that the remaining synchronizer rings are not pinched on their respective gear cones. If necessary, loosen the rings with a screwdriver.
20. Apply sealant to rear crankcase alignment surface (photo).
21. Gently lower the main cowl onto the rear crankcase, making sure the driver pins and positioning mechanism are seated in their respective holes (photo).
22. Prepare the special tool to install the input shaft bearing. It is not permissible to simply drive the bearing into place; the synchronizer rings can be damaged. It is also not possible to install the bearing circlip. GM Tool No. KM-461 (photo). It is made from a cut metal tube to provide a clamp to grip the input shaft. Two side bolts are used to push the bearing into the housing, using metal blocks to prevent damage to the bearing.
23. Before installing the bearing, heat the housing around the bearing seat to approximately 100°C.
24. Place the bearing (with retaining ring) above the input shaft, using a special tool, insert it into the housing (photo). Check that the inner groove of the circlip is visible on the input shaft.
25. Remove the tool, then install the inner circlip on the input shaft.
26. Engage neutral gear. Rotate the input shaft to make sure that the synchronizer rings do not get pinched on their cones.
27. Insert the body bolts, tighten them evenly with the tightening torque specified specification (photo).
28. Insert the front bolt for fastening the shaft of the intermediate reverse gear, tighten with a tightening torque regulated specification.
29. Remove the rubber O-ring from the clutch bearing guide bush. Clean the bearing surface, drive in a new seal using a suitable size metal tube or socket. The closed side of the stuffing box must be inside the sleeve. Install a new rubber o-ring (photo).
30. Lubricate the gland lug, then install the clutch release bearing guide bush, being careful not to damage it in the input shaft grooves. Insert the bolts, tighten them with a tightening torque, regulated specification (photo).
31. Insert the shift lever shaft retainer pin and spring, making sure the pin roller is horizontal. Drive the lid into the body with a mallet.
32. Install the speedometer drive gear and shroud. Insert and tighten the bolt.
33. Insert and clamp the reverse lamp switch (photo).
34. Install the release bearing and lever as described in Section 5.
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