a) Install the secondary shaft into the intermediate support by pressing it in and lightly tapping it on the intermediate support.
b) Install the secondary shaft center bearing retaining ring.
Note: Make sure the retaining ring is flush with the surface of the intermediate support.
2. Installing the primary shaft.
a) Apply grease to the 13 needle bearing rollers and insert the needle bearing rollers into the center hole of the input shaft.
b) Install the primary shaft onto the secondary shaft, ensuring that the grooves of the synchronizer ring match the synchronizer crackers.
3. Installing the intermediate shaft.
a) Install the snap ring onto the intermediate shaft rear bearing.
b) Install the intermediate shaft and rear shaft bearing into the intermediate support.
c) While holding the intermediate shaft, press the rear shaft bearing into the intermediate support.
4. Install the secondary shaft rear bearing holder and tighten the mounting bolt using a special wrench.
Tightening torque - 18 Nm
5. Install the reverse intermediate gear and its shaft on the intermediate support. Install the shaft stopper and tighten the mounting bolt.
Tightening torque: 17 Nm
6. Install the reverse gear shift lever bracket and tighten the two mounting bolts.
Tightening torque - 18 Nm
7. Insert the ball into the intermediate shaft and install the spacer sleeve.
8. Installing the intermediate shaft fifth gear gear assembly with synchronizer No.3 and needle bearing.
a) Apply transmission oil to the needle bearing rollers.
b) Install the fifth gear gear assembly with synchronizer No.3 and needle bearing.
9. Installing the fifth gear synchronizer ring and hub.
a) Place the synchronizer ring on the hub.
b) Remove the intermediate support assembly from the vice and place it as shown in the figure.
c) Using a press and a tool head (22 mm), install the fifth gear synchronizer hub so that the grooves of the synchronizer ring exactly match the synchronizer crackers.
d) Place the intermediate support in a vice.
10. Installing the retaining ring.
a) Select the retaining ring so as to ensure minimum axial clearance.
| Label | Thickness, mm |
| A | 2,80-2,85 |
| IN | 2,90-2,85 |
| WITH | 2,90-2,95 |
| D | 2,95 - 3,00 |
| E | 3,00 - 3,05 |
| F | 3,05-3,10 |
| G | 3,10-3,15 |
b) Using a copper rod and a hammer, install the retaining ring onto the intermediate shaft.
11. Using a feeler gauge, measure the axial clearance of the intermediate shaft fifth gear.
Nominal clearance - 0.10 - 0.30 mm
Maximum gap - 0.30 mm
12. Installing gear shift rod No.2 and gear shift forks No.1 and No.2.
a) Install gear shift forks No.1 and No.2.
b) Install gear shift rod No.2 through the intermediate support, and gear shift forks No.1 and No.2.
c) Install and tighten the shift fork No.2 mounting bolt.
Tightening torque - 20 Nm
13. Installing gear shift rod No.1.
a) Apply grease to locking pin No.2 and install it into gear shift rod No.1.
b) Using the magnetic rod, install the locking pin No.1 into the hole in the intermediate support.
c) Install gear shift rod No.1 through the intermediate support and gear shift fork No.1.
d) Install and tighten the shift fork No.1 mounting bolt.
Tightening torque - 20 Nm
14. Installing gear shift rod No.3 and reverse gear engagement linkage assembly with fork.
a) Install the pin and fork on the reverse gear engagement linkage and secure them with two retaining rings.
b) Install the reverse gear selector lever onto the selector lever bracket.
c) Apply grease to locking pin No.4 and insert it into gear shift rod No.3.
d) Using a magnetic rod, install locking pin No.3 into the hole in the intermediate support.
d) Install gear shift rod No.3 through the intermediate support and the reverse gear engagement fork.
e) Using a punch and hammer, drive the pin into the reverse gear engagement fork.
15. Installing the head of the reverse gear engagement rod, the fifth gear engagement fork, and gear shift rods No.4 and No.5.
a) Place the head of the reverse gear engagement rod onto No.3 gear shift rod.
b) Install gear shift fork No.3.
c) Using a magnetic rod, insert the ball into the head of the reverse gear engagement rod.
d) Install gear shift rod No.4 as shown in the figure.
d) Using the magnetic rod, insert the locking ball No.1 into the intermediate support.
e) Install gear shift rod No.4 through the intermediate support.
g) Using a punch and hammer, drive the pin into the No.3 gear shift fork.
c) Install gear shift rod No.5 through the head of the reverse gear engagement rod and the intermediate support.
i) Using a punch and hammer, drive the pin into the head of the reverse gear engagement rod.
16. Using a brass rod and hammer, install the three snap rings onto the shift rods.
17. Installing threaded plugs.
a) Insert four balls and springs into the intermediate support.
Note: Insert the short spring from the bottom of the intermediate support.
b) Apply sealant to the threads of the plugs.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
c) Insert the threaded plugs and tighten them with a socket wrench under the Allen bolt.
Tightening torque: 19 Nm
18. Remove the intermediate support from the vice, unscrew the bolts, remove the nuts and plate washers.
19. Install the gearbox housing,
a) Apply sealant to the gearbox housing (see picture).
Sealant: THREE BOND 1231, or equivalent.
b) Install the intermediate support as shown in the figure.
c) Install the gearbox housing on the intermediate support, as shown in the figure.
20. Installing the primary shaft bearing holder.
a) Install the retaining rings on the primary and intermediate shaft bearings.
b) Install the bearing retainer with a new gasket.
c) Apply sealant to the threads of the holder mounting bolts.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
d) Install and tighten the bolts.
Tightening torque: 17 Nm
21. Installing the transfer case adapter, shaft and gear shift lever housing.
a) Apply sealant to the transfer case adapter as shown in the figure.
Sealant: THREE BOND 1231, or equivalent.
b) Install the transfer case adapter and secure it with eight bolts.
Tightening torque: 37 Nm
c) Install the gear shift lever housing into the transfer case adapter as shown in the figure.
d) Insert the gear shift lever shaft into the transfer case adapter through the gear shift lever housing.
d) Install and tighten the gear shift lever housing mounting bolt.
Tightening torque - 38 Nm
e) Using the special tool, install and tighten the plug.
Tightening torque: 37 Nm
22. Installing the threaded plug.
a) Apply sealant to the plug threads.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
b) Install the locking ball, spring and plug. Tighten the plug.
Tightening torque: 19 Nm
23. Checking after installation of the transfer case adapter.
a) Make sure that the primary and secondary shafts rotate without jamming.
b) Make sure that all gear shifts are smooth and clear.
24. Installing limit pins.
a) Install the black pin on the reverse and fifth gear side.
b) Insert another stop pin and tighten the pins.
Tightening torque: 27 Nm
25. Install the gearshift lever cover and a new gasket. Install and tighten the four cover mounting bolts.
Tightening torque - 18 Nm
26. Install the transfer case control lever cover and a new gasket. Install and tighten the four cover mounting bolts.
Tightening torque - 18 Nm
27. Installing the clutch housing.
a) Install the clutch housing.
b) Apply sealant to the threads of the crankcase mounting bolts marked "A" in the figure.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
c) Install and tighten the nine mounting bolts.
Tightening torque: 37 Nm
28. Install the reversing light switch.
Tightening torque: 37 Nm
29. Install the clutch release fork and bearing.