2. Lubricate the release bearing guide bush mounting bolts with a sealant "Loctite Frenetanch", the edges of the seal - with grease. Insert the release bearing guide sleeve together with the new gasket into the front part of the crankcase (clutch housing) and screw it with bolts.
3. Install the outer race of the right differential bearing in the front part of the gearbox housing.
4. Install four bushings in the front part of the crankcase to center the intermediate bearing plate.
5. Install the gear selector lever assembly into the front of the crankcase by inserting the inner lever together with the lever assembly shaft inside the crankcase, the gasket and the outer lever outside the crankcase, and then secure the lever assembly with a cotter pin connecting the shaft to the outer gear selector lever.
6. Insert the differential, cotter pin and reverse gear lock spring into the front part of the gearbox housing.
7. Lubricate the surface of the connection between the intermediate bearing plate and the surface of the front part of the gearbox housing with glue "Loctite Scelmetal".
8. Install the intermediate bearing plate on the surface of the front part of the gearbox housing, lubricate the intermediate plate mounting bolts with silicone sealant "Loctite Frenetanch", tighten the bolts to a torque of 50 Nm and remove excess glue.
9. Attach the gear assemblies together with both shafts to the fork assembly with their axles and insert into the gearbox housing.
10. Insert the selector into the cage, then install the cage so that the selector pin simultaneously enters the fork cutouts and the cage engages with the teeth of the inner gear selector lever.
11. Compress the selector axle spring with its two washers and insert it from the outside between the selector sleeve and the selector axle hub of the intermediate plate.
12. Place a gasket on the selector axle and insert the selector axle from the outside sequentially into the holes: the outer hub of the intermediate plate selector axle, the spring with plates, the selector cage with the selector and the inner hub of the intermediate plate selector axle. Install the selector mounting pin on its axle.
Article republished from the website www.PeugeotBook.ru
13. Insert the reverse gear forks and press the reverse gear fork axle until it stops.
14. Insert the reverse gear pinion into the reverse gear fork slot, the reverse gear pinion shaft and the bushing.
15. Degrease the surface of the connection between the front and middle parts of the gearbox housing and lubricate it with a thin layer of silicone sealant (e.g, "Framet Autojoint").
16. Install the middle part of the crankcase onto the front part and tighten the mounting bolts to a torque of 17.5 Nm.
17. Install two plates securing the secondary shaft bearing by tightening two mounting screws.
18. Install the 5th gear on the end of the primary shaft (without supporting the gearbox housing), and also install the spring gasket and sealing ring.
19. Install the 5th gear on the secondary shaft together with the raceway, needle bearing and support pad.
20. Install the synchronizer unit at the end of the secondary shaft (hub-sliding sleeve) 5th gear together with forks.
21. Engage 5th gear by moving the synchronizer sleeve, and another gear to fix the gearbox shafts.
22. Tighten the nut and washer at the end of the secondary shaft to a torque of 137.5 Nm.
23. Shift the gearbox into neutral (turn off the gears).
24. Drive in the cotter pin for securing 5th gear.
25. Install the rear crankcase cover, tightening the bolts to a torque of 17.5 Nm.
26. Install the speedometer drive shaft by screwing its mounting bolt to the gearbox housing.
27. Install the clutch release bearing at the front of the gearbox.
28. Install the axle shaft sealing rings into the gearbox housing. Before installing the axle shafts, the sealing edges of the rings should be coated with grease.