2. Manually move the 5th gear synchronizer to the engaged gear position and then use an Allen key to loosen the bolts securing the 5th gear fork (see figure 6.29).
Figure 6.29. Hexagon head screws securing 5th gear fork (shown by arrows) — gearbox F10.5
Figure 6.30. 5th gear pinion parts removed from the driven shaft - F10.5 gearbox
3. Remove the retaining ring from the end of the driven shaft and use a puller to remove the 5th gear synchronizer from the driven shaft.
4. After this, you can remove the 5th gear from the driven shaft together with its bearing, split thrust washer and thrust washer retaining ring.
5. Remove the snap ring from the end of the drive shaft and pull or press the 5th gear off the shaft. If you use a puller, be careful not to damage the drive shaft and place something under the jaws to distribute the load.
6. Using a hex key, loosen the screws securing the 5th gear rod locking pawl to the intermediate plate (see figure 6.31).
Figure 6.31. Screws securing the 5th gear rod locking pawl (shown by arrow) — gearbox F10.5.
7. Pry up the retainer plugs and remove them from the intermediate plate. Remove the springs and plungers of the retainers. Plugs damaged during removal must be replaced with new ones.
8. Move the 5th gear rod to the engaged gear position and move the 2nd gear fork to engage 2nd gear.
9. Using a hex key, loosen the screws securing the locking plunger jumper. Remove the jumper and return the gears to neutral position (see figure 6.32).
Figure 6.32. Locking plunger jumper mounting screws (shown by arrow) — gearbox F10.5
Figure 6.33. Removing the 5th gear rod linkage — F10.5 gearbox.
10. Drive out the cylindrical pins securing the 3/4 gear and reverse gear forks. Remove the forks and rods.
11. Remove the 5th gear rod link from the intermediate plate.
12. Remove the retaining rings holding the driven and driving shafts on the intermediate plate. After this, you can pull out the gear blocks together with the reverse intermediate gear, 1/2 gear fork and rod.
13. Further overhaul is carried out in the same way as described in section 8 for the F10.4 gearbox. Please note that the 1st and 5th gear pinions on the driven shaft of the F10.5 gearbox have split needle bearings.
14. The gearbox is assembled in the reverse order. Please note the following points:
- a. Secure the locking plunger jumper and the 5th gear rod pawl with new screws. The threads of these screws must be coated with thread locking compound and they must be replaced after each removal.
- b. Note that the longer plug is for the 3/4 gear lock (see figure 6.34).
- c. Before installing the 5th gear synchronizer on the driven shaft, it should be heated to 100°C.
- g. The end cap plug threads do not need to be coated with sealant.
Figure 6.33. Removing the 5th gear rod linkage — F10.5 gearbox.
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