Using the KM 452 and KM 454 devices, install the primary shaft needle bearing into the gearbox housing socket with the inscription facing the inside of the gearbox.
Install the clutch release bearing guide sleeve. Install the bearing, fork and clutch release lever, after applying a thin layer of molybdenum disulfide grease to the friction surface of the bearing on the guide sleeve.
Assemble the synchronizers of the first and second gears, and then the third and fourth gears. Insert the springs on both sides of the clutch hubs of the synchronizers (see photo), inserting their ends into the same groove of the cracker so that the free end of each spring moves away from the clutch hub. The ends of the spring of the synchronizer of the first gear should cross at a distance of 18 mm, and synchronizers of the second, third and fourth gears - at a distance of 8 mm. Install crackers in the grooves of the clutch hubs.
Place the third gear pinion on the front part of the secondary shaft, having previously lubricated its inner diameter with oil for highly loaded parts.
Place the synchronizer locking ring of the third gear onto the neck of the third gear pinion. Heat the synchronizer locking ring to 100°C, monitoring the heating temperature with a thermochromic pencil, and press it onto the shaft. Lubricate the secondary shaft surfaces with oil for highly loaded parts.
Lock the hub of the III and IV gear clutch with a new retaining ring.
Place the synchronizer locking ring and the 4th gear on the secondary shaft.
Lubricate the secondary shaft journals with gearbox oil. Press the spacer sleeve and the main gear pinion onto the shaft, preheating them to 100°C. The grooves in the spacer sleeve should face the pinion, and the flange on the pinion should be on the sleeve side. The primary and secondary shaft pinions should be replaced simultaneously in accordance with the markings in the form of annular grooves at the tops of the teeth. Secure the main gear pinion with a new retaining ring.
Turn the secondary shaft over. Put the 2nd gear pinion on the shaft, having previously lubricated the inner diameter of the pinion with oil for highly loaded parts.
Place the 2nd gear synchronizer locking ring on the 2nd gear gear.
Install the synchronizer of the 1st and 2nd gears in the same way as the synchronizer of the 3rd and 4th gears.
Lubricate the shaft journal with gearbox oil. Heat the spacer sleeve and press it onto the shaft, directing the grooves on the sleeve toward the 2nd gear pinion. Install the ball bearing, having first installed a new retaining ring, which ensures the secondary shaft is fixed in the rear gearbox cover.
Place a new retaining ring on the rear end of the primary shaft to ensure its fixation in the rear cover of the gearbox.
Press on the rear ball bearing of the primary shaft using the KM 311/2 tool; the closed side of the bearing must face outward. Install the washer and new snap ring.
Press the primary shaft with the smaller diameter splines into the gear block holes, being careful not to damage the gear block splines.
Insert the locking ball into the socket of the reverse intermediate gear axle and press the axle into the rear cover of the gearbox.
Install the clamps in the rear cover of the gearbox. Before installing the clamps in the rear cover, connect the rod and the fork of the first-second gear shift with a new pin; the end of the pin should protrude by approximately 2 mm.
Place the reverse intermediate gear on the axle, holding it at a distance from the rear cover using a device made from scrap materials.
Heat the rear cover of the gearbox using a heater with a fan and insert the secondary and primary shafts, the fork rod and the fork for shifting 1st and 2nd gears into it as an assembly.
Install the pressure washer on the reverse intermediate gear shaft and secure the shafts in the gearbox rear cover with retaining rings, inserting the retaining rings into the grooves of the rear cover.
Install the rods and forks for shifting III and IV gears and engaging reverse gear. Secure the gear shift forks to the rods with pins.
Install the springs and lock plugs into the rear cover, having first engaged 2nd gear.
Apply a new gasket to the rear cover of the gearbox using bearing grease 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 running light switch, if provided by the design.
Connect the gear shift linkage using a new pin.
Install the oil seal into the gearshift mechanism cover, filling the cavity between the working edges of the oil seal with protective grease 1948 814/90 001 804.
Insert the gear shift rod and linkage into the cover and pin it in place.
Place the intermediate gearshift lever and pressure spring onto the guide sleeve. Install a new retaining ring.
Apply bearing grease to the cover gasket and install the gearshift cover with the gasket. The gears must be in neutral.
Fill the gearbox with oil through the ventilation hole and screw the plug into the gearshift mechanism cover.
Note: Replacement of synchronizer locking rings, replacement of speedometer drive gears, disassembly and assembly of differential, replacement of wheel drive shaft seals are performed without removing the gearbox.
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