Unscrew the ventilation plug of the gearbox housing from the gearshift mechanism cover.
Remove the gear shift cover.
Place the lid on the stand.
Remove the pin, snap ring, bushing, pressure spring and intermediate gear shift lever.
Knock out the pin from the leash and remove the gear shift drive rod.
Remove the pin from the rubber bushing by filing down the head of the riveted pin. Remove the plug with the grease from the box cover.
Remove the driven shaft-gear of the speedometer drive; to do this, unscrew the hex bolt and use a screwdriver to remove the guide sleeve and driven shaft gear.
Unscrew the reverse light switch, if installed, placing a container underneath to collect the oil.
Engage the 2nd gear by sliding the 1st-2nd gear shift fork back with a screwdriver (see photo).
Unscrew the rear cover mounting bolts and remove it together with the shafts. Install the rear cover on the stand.
Remove the plugs and retainer springs.
Set the gear shift lever to neutral and knock out the pins from the forks of shifting III and IV gears and engaging reverse gear, and then from the fork of shifting I and II gears. Pull the rods out of the forks.
Use pliers to remove the retaining ring from the groove of the primary shaft, and then the retaining ring of the secondary shaft.
Remove the shafts Heat the upper part of the gearbox rear cover to approximately 80°C using a heater with a fan, making sure that the shafts do not fall out. The reverse intermediate gear can be removed by hand without preheating.
Remove the fasteners from the rear cover of the gearbox.
Clamp the axle of the intermediate reverse gear pinion in a vice and knock out the pinion by striking the rear cover of the gearbox with a brass punch.
Separate the primary shaft from the gear block, remove the retaining ring, and then press the inner bearing ring from the rear end of the primary shaft.
Remove the retaining ring and press the bearing, spacer sleeve and 1st gear pinion off the secondary shaft. Remove the retaining ring and press the 1st and 2nd gear synchronizer and 2nd gear pinion off the shaft. Turn the secondary shaft over, remove the retaining ring and press the main gear pinion off, then remove the spacer sleeve and press the 4th gear pinion off. If this is difficult, use the KM 479 mandrel installed in the gear groove.
Remove the retaining ring and press off the synchronizer of the third and fourth gears, then remove the third gear gear.
Disconnect the clutch release fork from the clutch release lever and remove the clutch release bearing.
Remove the sealing ring and remove the secondary shaft cylindrical roller bearing from the gearbox housing.
Warning: When removing the pins from the 3rd and 4th gear shift forks and engaging reverse, place a wooden block under the fork rods so that the guide bushings remain in the upper position.
When removing the reverse intermediate gear shaft, take measures to prevent the retainer ball from falling out.
(Source is on this resource: OPELBOOK)
If defects or wear marks are detected on the teeth of the primary shaft gear block, the primary shaft gear block and the corresponding secondary shaft gears should be replaced.
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