When assembling the gearbox of a front-wheel drive car, perform the reverse steps to disassembly. It is best to entrust this process to professionals, thus you can save not only money, time, but also your nerves. If this is not possible, then all operations should be carried out carefully, so as not to remove the gearbox again and not to alter it.
Necessary
- - mandrels 67.7853.9565, 67.7853.9563, 67.7853.9575;
- - torque wrench;
- - automotive sealant.
Instructions
Step 1
Assemble the differential. Pre-lubricate the planetary gears and side gears with oil. Install the speedometer drive gear. Take a mandrel 677853.9565 and press the inner bearing races onto the differential case.
Step 2
Install the clutch housing on the stand. Take a mandrel 677853.9563 and press the stem oil seal into the seat. Insert the gear selector rod into the hole in the crankcase. Secure the stem lever to it. Install an oil sump into the hole for the front bearing of the output shaft. Take a mandrel 67.7853.9574 and press the outer rings of the roller bearings of the input and output shafts, complete with cages, into the seats of the clutch housing.
Step 3
Press the front bearing inner race onto the input shaft. Take a mandrel 67.7853.9575 and press in the outer rings of the differential bearings. Put on the gear selection mechanism. Make sure the selector lever is in the correct position in relation to the selector lever. Lock the gear selection mechanism.
Step 4
Install the axle shaft seals. Press the oil seal with the right notch into the clutch housing, press the oil seal with the left notch into the gearbox housing. Arrows on their bodies should be directed in the direction of the vehicle. Install the input shaft oil seal into the clutch housing so that its working edge is on the polished shaft collar.
Step 5
Install the differential into the crankcase. Fix one of the side gears on the side of the crankcase with a plug that is used when transporting the gearbox. Press ball bearings onto the input and output shafts. Install them in the clutch housing together with the gears. Then put the axle with the reverse gear. The reverse fork should fit into the idler groove. Install the shift rods and secure the forks to the rods.
Step 6
Place the magnet in the crankcase socket. Install the differential bearing shim in the same place. Take a mandrel 67.7853.9575 and press in the differential tapered roller bearing outer race. Reinstall the speedometer drive. Apply sealant to the clutch housing around the perimeter. Install the transmission housing and secure it. Install the locating rings in the grooves of the shaft bearings. Install the stop plate. Take an impact drill / screwdriver and tighten the screws, replacing the split washers with new ones.
Step 7
Install on the input shaft the drive gear of the "fifth" gear, on the output shaft in series the washer, the bushing, the driven gear of the "fifth" gear, the blocking ring, the synchronizer and the fork of the "fifth" gear, then the thrust plate of the synchronizer nuts. Screw on the nuts and tighten them with a torque wrench, then stamp the nuts. Replace the rod clamps and reverse forks, tighten the clamp plugs. Secure the fifth gear fork bolt. Apply sealant to the transmission case. Install the rear cover and secure it with nuts.
