Using tools KM 452 and KM 454, install the input shaft needle bearing in the gearbox housing housing with the inscription inside the gearbox.
Install the clutch release bearing guide bush. Install the bearing, yoke and release lever after applying a thin layer of molybdenum disulphide grease to the friction surface of the bearing on the guide bush.
Assemble synchronizers of I and II gears, and then III and IV gears. Insert springs on both sides of the hubs of the synchronizer couplings (see photo), leading their ends into the same cracker groove so that the free end of each spring moves away from the coupling hub. The ends of the 1st gear synchronizer spring must cross at a distance of 18 mm. and synchronizers II, III and IV - at a distance of 8 mm. Install crackers in the grooves of the coupling hubs.
Put the 3rd gear gear on the front part of the secondary shaft, having previously lubricated its inner diameter with oil for high-loaded parts.
Slide the 3rd gear synchronizer blocking ring onto the 3rd gear pinion journal. Heat the synchronizer blocking ring to 100°C, controlling the heating temperature with a thermochromic pencil, and press it onto the shaft. Lubricate the hardness of the output shaft with oil for heavy-duty parts.
Lock the 3rd and 4th gear clutch hub with a new circlip.
To put on a secondary shaft a blocking ring of the synchronizer and a gear wheel of IV transfer.
Lubricate the mainshaft journals with gearbox oil. Press the spacer sleeve and main gear on the shaft, preheating them to 100°C. In this case, the grooves of the spacer sleeve must face the gear, and the shoulder on the gear must be located on the side of the sleeve. The replacement of the gears of the primary and secondary shafts must be carried out simultaneously in accordance with the marking in the form of annular grooves at the tops of the teeth. Secure final drive gear with a new circlip.
Turn over the output shaft. Put on the gear shaft of the 2nd gear, having previously lubricated the inner diameter of the gear with oil for high-loaded parts.
Slide the 2nd gear synchronizer ring onto the 2nd gear gear.
Install the 1st and 2nd gear synchronizer in the same way as the 3rd and 4th gear synchronizer.
Lubricate the shaft journal with gearbox oil. Heat the spacer bushing and press it onto the shaft, directing the grooves on the bushing towards the 2nd gear gear. Install the ball bearing, having previously installed a new retaining ring, which ensures the fixation of the output shaft in the rear cover of the gearbox.
Install a new retaining ring on the rear end of the input shaft to ensure its fixation in the rear cover of the gearbox.
Press on the input shaft rear ball bearing using tool KM 311/2; the closed side of the bearing must face outwards. Install washer and new circlip.
Press the input shaft with the smaller diameter splines into the holes in the gear block, being careful not to. not to damage the splines of the gear cluster.
Insert the locking ball into the seat of the reverse intermediate gear axle and press the axle into the gearbox rear cover.
Install the clips in the rear cover of the gearbox. Before installing the latches in the rear cover, connect the stem and the I-II shift fork with a new pin; the end of the pin should protrude approximately 2 mm.
Slide the reverse idler gear onto the axle, keeping it away from the rear cover using a tool. made from scrap materials.
Using a heater with a fan, heat the rear cover of the gearbox and insert the secondary and primary shafts and the fork rod and the shift fork of 1st and 2nd gears into it.
Install the pressure washer on the axis of the reverse intermediate gear and secure the shafts in the gearbox rear cover with circlips by inserting the circlips into the grooves of the rear cover.
Install the rods and forks for shifting III and IV gears and reverse gear. Secure the shift forks to the shafts with pins.
Install the springs and plugs of the clamps in the rear cover, having previously engaged the 2nd gear.
Place a new gasket on the bearing grease on the rear cover of the gearbox and install the assembled rear cover on the gearbox housing. Tighten the mounting bolts.
Install the driven shaft-gear of the speedometer drive, securing it with a locking plate, and install the daytime light switch, if it is provided for by the design.
Connect the gearshift linkage with a new pin.
Install the oil seal in the gearshift cover. by filling the cavity between the seal lips with protective grease 1948 814/90 001 804.
Insert the linkage and the shift lever into the cover and pin.
Slide the intermediate shift lever and pressure spring onto the guide bushing. Install a new retaining ring.
Place the gasket on the cover on the bearing grease and reinstall the gearshift cover with gasket. In this case, the gearbox gears must be in the neutral position.
Pour oil into the gearbox through the vent hole and screw the plug into the gearshift cover.
Note. Replacement of locking rings of synchronizers, replacement of speedometer drive gears, disassembly and assembly of the differential, replacement of wheel drive shaft seals are performed without removing the gearbox.
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