Assembly of the 038M1 gearbox

Assembly of Manual Transmission 038M1 — step-by-step instruction

1. Clean the mounting surfaces of the transmission case and the intermediate plate. Apply a bead of sealant of 1.2 mm diameter to the mounting surface of the transmission case and the intermediate plate.

We examined the disassembly of the gearbox in the article — «Gearbox disassembly».

Materials used and precautions:

For sealing the mounting surfaces, use sealant and apply a bead of 1.2 mm diameter.
Install the parts no later than ten minutes after applying the sealant.
To lubricate the input shaft splines and the release fork support head, use molybdenum-based grease.
Tighten the mounting bolts to the recommended torque; for multiple bolts, follow the diagonal sequence.
Use new sealing washers when installing the plugs.
When seating the rear case, a few light blows with a plastic mallet are permitted.

Step-by-step assembly

1. Preparation and application of sealant to the transmission case and intermediate plate

Clean the mounting surfaces of the transmission case and the intermediate plate. Apply a bead of sealant of 1.2 mm diameter to the mounting surface of the transmission case and the intermediate plate.

Note: install the transmission case no later than ten minutes after applying the sealant.

Applying sealant to the case and plate — Fig. 1. Applying a bead of sealant of 1.2 mm diameter

2. Installation of the transmission case

Install the transmission case onto the intermediate plate of the gearbox.

Installing the case onto the intermediate plate — Fig. 2. Installation of the transmission case

3. Installation of the bearing snap rings

Install the input shaft bearing snap ring and the front intermediate shaft bearing snap ring.

Installing the bearing snap rings — Fig. 3. Snap rings of the input and intermediate shaft bearings

4. Application of sealant to the case and front cover

Clean the mounting surfaces of the transmission case and the front cover. Apply a bead of sealant of 1.2 mm diameter to the mounting surface of the transmission case and the front cover.

Note: install the front cover no later than ten minutes after applying the sealant.

Applying sealant to the front cover — Fig. 4. Applying sealant to the mounting surface of the front cover

5. Installation of the front cover

Install the front cover and secure it with eight bolts. Tighten the bolts to the recommended torque.

Tightening torque: 11.55–21.45 N·m.

Note: tighten the bolts in a diagonal sequence.

Installing the front cover and tightening bolts — Fig. 5. Securing the front cover with eight bolts

6. Installation of the shift shaft and shift block

Install the shift shaft and the gear shift block onto the rear case of the gearbox.

Installing the shift shaft and block — Fig. 6. Installation of the shift shaft and gear shift block

7. Application of sealant to the rear case

Clean the mounting surface of the rear case. Apply a bead of sealant of 1.2 mm diameter to the mounting surface of the rear case.

Note: install the rear case no later than ten minutes after applying the sealant.

Applying sealant to the rear case — Fig. 7. Applying sealant to the mounting surface of the rear case

8. Installation of the rear case

Install the rear case of the gearbox.

Note: apply a few light blows to the rear case using a plastic mallet.

Installing the rear case — Fig. 8. Seating the rear case with a plastic mallet

9. Tightening the rear case mounting bolt

Screw in and tighten the mounting bolt to the recommended torque.

Tightening torque: 25.9–48.1 N·m.

Fig. 9. Tightening the rear case mounting bolt

10. Screwing in the shift block bolt

Screw in the bolt securing the shift block to the shift shaft.

11. Installation of the positioning mechanism components

Install the positioning mechanism components.

Installing the positioning mechanism components — Fig. 11. Positioning mechanism components

12. Application of sealant to the shift lever cover

Clean the mounting surface of the shift lever cover. Apply a bead of sealant of 1.2 mm diameter to the mounting surface of the shift lever cover.

Note: install the shift lever cover no later than ten minutes after applying the sealant.

Fig. 12. Applying sealant to the shift lever cover

13. Installation of the shift lever cover

Install the shift lever cover and secure it with six bolts.

Tightening torque: 14.4–21.6 N·m.

Installing the shift lever cover — Fig. 13. Securing the shift lever cover with six bolts

14. Installation of the speedometer driven gear

Install the speedometer driven gear.

Bolt tightening torque: 6–10 N·m.

Installing the speedometer driven gear — Fig. 14. Speedometer driven gear

15. Installation of the reverse light switch

Screw in and tighten to the recommended torque the reverse light switch.

Tightening torque: 35.2–52.8 N·m.

Installing the reverse light switch — Fig. 15. Reverse light switch

16. Installation of the clutch housing

Install the clutch housing onto the transmission case and secure it with a bolt. Tighten the bolt to the recommended torque.

Tightening torque: 15.5–20.6 N·m.

Installing the clutch housing — Fig. 16. Securing the clutch housing

17. Installation of the release fork support

Screw in and tighten to the recommended torque the clutch release fork support.

Tightening torque: 38–56 N·m.

Installing the release fork support — Fig. 17. Clutch release fork support

18. Application of grease to the splines and support head

Apply molybdenum-based grease to the input shaft splines and the release fork support head.

Applying grease to the splines and support head — Fig. 18. Applying molybdenum grease to the splines and support head

19. Installation of the release fork, bearing and protective cover

Install the release fork, the release bearing and the release fork protective cover.

Installing the release fork and bearing — Fig. 19. Release fork, release bearing and protective cover

20. Installation of the clutch slave cylinder

Install the clutch slave cylinder and secure it with bolts. Tighten the bolts to the recommended torque.

Tightening torque: 8.19–15.21 N·m.

Installing the clutch slave cylinder — Fig. 20. Clutch slave cylinder

Fig. 21. Securing the clutch slave cylinder

21. Installation of the plugs and sealing washers

Install new sealing washers. Screw in and tighten the hex plugs of the gearbox.