Remove:
- air breather (2);
- drain plug (5);
Special tools for dismantling the gearbox:
1a - universal puller bracket «Facom U53 K2»;
1b - tools for tearing off the universal puller «Facom U53 T2»;
2 - mandrel for removing and installing the outer ring of the input shaft bearing 0317-AR;
3 - 5th gear clutch puller 0317-Y;
4 - fixture for pinion stop 0317-JZ;
5 - puller of fingers for fixing the gear lever 0317-A1.
- level check plug (6);
- two axle seals (4);
- speed sensor drive gear support (3).
Remove release bearing (7) complete with fork (8).
Removing the 5th gear
Loosen the bolts (9) and remove the cover (10).
Shift into 5th gear, remove your finger (13) fork fasteners.
Move control to a dead center.
Note. The plug must remain in place.
Engage another gear, blocking the rotation of the shafts.
Remove retaining ring (12).
Loosen nuts (14) And (11).
Remove the clutch using tool 3.
Mark the position of the coupling (15) in relation to the synchronizer (16).
Remove the clutch and synchronizer assembly (15) And (16) with fork (17).
Remove:
- 5th gear motor gear (18);
- thrust ring (19);
- spacer (20).
Removing the gearbox housing
Loosen the bolts (22) securing the output shaft bearing and remove the retaining plate (24) fork axles.
Remove the lock screw (23) axles of the intermediate reverse gear and unscrew the bolts (21).
Remove snap ring (25) (if necessary, use two sharp tools and lift the shaft to facilitate its release).
Remove the gearbox housing.
Note. Use a wooden mallet to separate the crankcase from the center rings.
Removing the primary and secondary shafts
Remove the oil pan (26).
Remove the reverse sliding gear axle (28).
Rotate and remove the 5th gear axle (27).
Remove the fork axle (29), by pulling it up.
turn the plug (30).
Separate the shafts from the clutch housing by a few millimeters (up).
Turn the right side of the fork down.
Remove the plug (30).
Remove together primary and secondary shafts.
Remove the release bearing guide.
Removing the differential
Remove the bridge extension (31).
Reuse:
- speedometer drive worm (33).
- gasket (32);
- mounting washer (if installed).
Loosen the bolts (35) And (36).
Note. Differential housing (37) has notches «A» And «b» for easier removal.
Insert screwdrivers into slots «A» And «b», acting as levers.
Remove the differential housing (37) and differential block (38).