Unscrew the plug of the vent hole of the gearbox housing from the cover of the gear shift mechanism.
Remove gearshift cover.
Install the cover on the stand.
Remove the pin, snap ring, bushing, pressure spring and intermediate shift lever.
Knock out the pin from the leash and remove the gearshift linkage.
Remove the pin from the rubber bush by grinding off the head of the riveted pin. Remove the plug from the lid of the box with the lubricant embedded in it.
Remove the driven gear shaft of the speedometer drive; To do this, unscrew the hexagon head bolt and remove the guide bush and driven gear shaft with a screwdriver.
Unscrew the reverse light switch, if fitted. substituting a container to collect the oil.
Engage 2nd gear by sliding back the 1st-2nd gear shift fork with a screwdriver (see photo).
Unscrew the bolts securing the rear cover and remove it together with the shafts. Install the back cover on the stand.
Remove plugs and retainer springs.
Set the gear lever to the neutral position and knock out the pins from the shift forks of the III and IV gears and the reverse gear, and then from the shift fork of the I and II gears. Pull the rods out of the forks.
Remove the circlip from the input shaft groove with pliers, and then the circlip of the output shaft.
Take out the shafts. Heat the upper part of the gearbox rear cover to a temperature of approximately 80°C using a heater with a fan, making sure that the shafts do not fall out. The reverse intermediate gear is removed by hand without preheating.
Remove the clips from the back cover of the gearbox.
Clamp the shaft of the intermediate reverse gear in a vise and knock out the gear by hitting the back cover of the gearbox with a brass punch.
Separate the input shaft from the gear block, remove the retaining ring, and then press the bearing inner race from the rear end of the input shaft.
Remove the circlip and press the bearing, spacer and 1st gear off the output shaft. Remove the retaining ring and press the synchronizer of 1st and 2nd gears and the 2nd gear from the shaft. Turn over the output shaft, remove the circlip and compress the final drive gear, then remove the spacer and compress the 4th gear. using, in case of difficulty, the mandrel KM 479, installed in the gear groove.
Remove the retaining ring and press the 3rd and 4th gear synchronizer, then remove the 3rd gear gear.
Disconnect the clutch release fork from the clutch release lever and remove the clutch release bearing.
Remove the O-ring and remove the output shaft cylindrical roller bearing from the gearbox housing.
Warning. When removing the pins from the shift forks of III and IV gears and engaging reverse gear, place a wooden block under the fork rods so that the guide bushings remain in the upper position.
When removing the shaft of the intermediate reverse gear, take measures to prevent the detent ball from falling out.
If defects are found, signs of wear on the teeth of the input shaft gear block, the input shaft gear block and the corresponding output shaft gears should be replaced.
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