Disassembly of the 038M1 gearbox

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

The gearbox is disassembled for inspection and replacement of worn parts.

Materials used and precautions:

To remove covers and cases, use a plastic mallet — apply light blows, avoiding deformation of the seating surfaces.
To extract small items (steel balls, pins), use a magnetised rod.
Apply a thin layer of clean transmission oil to the needle bearings and conical surfaces of the gears.
Apply sealant to the plug threads before screwing them in.
Tighten the mounting bolts to the recommended torque; for multiple bolts, follow the diagonal sequence.
Select the snap rings so that the axial clearance is less than 0.1 mm.
Drain the oil from the gearbox into a suitable container; dispose of the used oil in accordance with environmental requirements.

General view of manual transmission 038M1 — Manual transmission 038M1: 1. Clutch housing. 2. Release fork spacer. 3. Release fork. 4. Release bearing. 5. Release fork protective cover. 6. Front cover. 7. Input shaft bearing snap ring. 8. Front intermediate shaft bearing snap ring. 9. Gearbox case. 10. Protrusion. 11. Cylindrical pin. 12. Hex threaded plug. 13. O-ring. 14. Shift shaft. 15. Shift block. 16. Screw. 17. Rear gearbox case. 18. Shift lever cover. 19. Component H of the positioning mechanism. 20. Component L of the positioning mechanism. 21. Reverse light switch. 22. Clip. 23. Hollow set pin.

Gearbox disassembly

1. Oil drain

Loosen the hex plug and remove the washer, then drain the oil from the gearbox.

Loosening the hex plug for oil drain — Fig. 1. Loosening the hex plug and draining the oil

2. Removal of the clutch slave cylinder

Loosen the mounting bolts and remove the clutch slave cylinder.

3. Removal of the boot, release fork and bearing

Remove the boot, the clutch release fork and the release bearing.

4. Removal of the reverse light switch

Remove the reverse light switch.

5. Removal of the release fork support

Remove the release fork support.

6–7. Removal of the clutch housing

Loosen the clutch housing mounting bolts.

Loosening the clutch housing bolts — Fig. 6. Loosening the clutch housing mounting bolts

Apply a few light blows to the clutch housing with the plastic mallet and remove it.

Fig. 7. Removal of the clutch housing with a plastic mallet

8. Removal of the shift lever cover

Loosen the six bolts securing the shift lever cover to the rear gearbox case, then remove the shift lever cover.

9. Removal of the positioning mechanisms

Remove the components of the left and right positioning mechanisms.

Removal of the positioning mechanism components — Fig. 9. Removal of the left and right positioning mechanism components

10. Loosening the bolt

Loosen the bolt.

11. Removal of the rear gearbox case

Loosen the bolt securing the rear case to the gearbox case, apply a few light blows to the rear case with the plastic mallet and remove the rear gearbox case.

12. Removal of the front cover

Loosen the bolts securing the front cover to the gearbox case.

Loosening the front cover bolts — Fig. 12. Loosening the front cover mounting bolts

Apply a few light blows to the front cover with the plastic mallet and remove the front gearbox cover.

13. Removal of the bearing snap rings

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

14. Removal of the gearbox case

Apply a few light blows to the gearbox case with the plastic mallet and remove it.

Removal of the gearbox case with a plastic mallet — Fig. 14. Removal of the gearbox case

Removal of the shift components

1–3. Removal of the spring and steel ball

Secure the intermediate plate in a vice. Loosen the spring threaded plug. Remove the spring and the steel ball using a magnetised rod.

Fig. 15. Securing the intermediate plate in a vice

Fig. 16. Loosening the spring threaded plug

Fig. 17. Removal of the spring and steel ball

4–8. Removal of the first/second shift forks and shafts

Loosen the bolts securing the first gear shift fork and the second gear shift fork.

Loosening the first/second shift fork bolts — Fig. 18. Loosening the first/second shift fork mounting bolts

Remove the snap rings of the first gear shift fork shaft and the second gear shift fork shaft.

Fig. 19. Removal of the fork shaft snap rings

Remove the second gear shift fork shaft and the second gear shift fork.

Fig. 20. Removal of the second gear fork shaft and fork

Remove the shift lock pin and the shift lock guide rod using a magnetised rod.

Fig. 21. Removal of the shift lock pin and guide rod

Remove the first gear shift fork shaft and the first gear shift fork.

Fig. 22. Removal of the first gear fork shaft and fork

9–11. Removal of the third gear shift fork and shaft

Remove the third gear shift fork snap ring.

Removal of the third gear fork snap ring — Fig. 23. Removal of the third gear shift fork snap ring

Remove the elastic cylindrical pin.

Fig. 24. Removal of the elastic cylindrical pin

Remove the third gear shift fork shaft and the third gear shift fork.

Fig. 25. Removal of the third gear fork shaft and fork

12–15. Removal of the lock mechanism and rocker bracket

Extract the short shift lock pin and the steel ball using a magnetised rod.

Fig. 26. Extraction of the short pin and steel ball

Extract the steel ball and spring from the reverse rocker.

Fig. 27. Extraction of the ball and spring from the reverse rocker

Remove the reverse rocker.

Loosen the bolts of the reverse rocker bracket and remove the bracket.

Fig. 29. Removal of the reverse rocker bracket

16–18. Removal of the speedometer gear

Remove the speedometer shaft snap ring.

Fig. 30. Removal of the speedometer shaft snap ring

Remove the speedometer drive gear and the steel ball.

Removal of the speedometer drive gear and ball — Fig. 31. Removal of the speedometer drive gear and steel ball

Remove the speedometer shaft snap ring.

Removal of the second speedometer shaft snap ring — Fig. 32. Removal of the speedometer shaft snap ring

19–24. Removal of the rear bearing and fifth gear components

Remove the output shaft rear bearing snap ring.

Removal of the rear bearing snap ring — Fig. 33. Removal of the output shaft rear bearing snap ring

Remove the output shaft rear bearing.

Fig. 34. Removal of the output shaft rear bearing

Remove the bushing.

Remove the fifth gear intermediate shaft.

Fig. 36. Removal of the fifth gear intermediate shaft

Remove the fifth gear synchroniser ring, the fifth gear intermediate shaft components and the needle bearing.

Fig. 37. Removal of the synchroniser ring and needle bearing

Remove the thrust washer and pin of the fifth gear.

Fig. 38. Removal of the thrust washer and pin of the fifth gear

25–31. Removal of the baffle, intermediate gear and shafts

Loosen the bolts of the output shaft bearing baffle and remove the bearing baffle.

Fig. 39. Removal of the output shaft bearing baffle

Extract the reverse intermediate gear shaft and the reverse intermediate gear.

Extraction of the reverse shaft and gear — Fig. 40. Extraction of the reverse intermediate gear shaft and gear

Remove the intermediate shaft rear bearing.

Fig. 41. Removal of the intermediate shaft rear bearing

Remove the intermediate shaft.

Fig. 42. Removal of the intermediate shaft

Remove the input shaft assembly.

Fig. 43. Removal of the input shaft assembly

Remove the output shaft bearing snap ring.

Fig. 44. Removal of the output shaft bearing snap ring

Apply a few blows to the intermediate plate and extract the output shaft assembly.

Fig. 45. Extraction of the output shaft assembly

Input shaft disassembly and assembly

Input shaft disassembly

1. Remove the fourth gear synchroniser ring and the input shaft needle bearing.

2. Remove the input shaft snap ring.

Fig. 48. Removal of the input shaft snap ring

3. Remove the input shaft bearing.

Fig. 49. Removal of the input shaft bearing

Input shaft assembly

1. Install the input shaft bearing.

Fig. 50. Installation of the input shaft bearing

2. Select the input shaft snap ring.

Note: select the input shaft snap ring so that the axial clearance is less than 0.1 mm.

Fig. 51. Selection of the input shaft snap ring

3. Install the input shaft snap ring.

Fig. 52. Installation of the input shaft snap ring

4. Install the fourth gear synchroniser ring.

Apply a thin layer of clean transmission oil to the conical surface of the fourth gear and then install the fourth gear synchroniser ring.

Fig. 53. Installation of the fourth gear synchroniser ring

Check the axial clearance between the fourth gear synchroniser ring and the fourth gear.

Standard value: 1.2 ± 0.5 mm.

Checking the synchroniser ring axial clearance — Fig. 54. Checking the fourth gear synchroniser ring axial clearance

5. Try to turn and press the synchroniser ring to check its operation.

Fig. 55. Checking the synchroniser ring operation

6. Install the input shaft needle bearing.

Apply a thin layer of clean transmission oil to the inner surface of the input shaft.

Applying oil to the inner surface of the shaft — Fig. 56. Applying oil to the inner surface of the input shaft

Install the input shaft needle bearing.

Output shaft disassembly

General view of the output shaft: 1. Second gear synchroniser hub snap ring. 2. Second gear synchroniser sleeve. 3. Second gear synchroniser expander ring. 4. Second gear synchroniser key. 5. Second gear synchroniser hub. 6. Third gear synchroniser ring. 7. Third gear needle bearing. 8. Third gear. 9. Output shaft. 10. Pin. 11. Second gear. 12. Second gear needle bearing. 13. First gear synchroniser inner ring. 14. First gear synchroniser intermediate ring. 15. Second gear synchroniser outer ring. 16. First gear synchroniser key. 17. Compression spring. 18. First gear synchroniser hub. 19. First gear synchroniser outer ring. 20. First gear synchroniser sleeve. 21. First gear synchroniser hub snap ring. 22. First gear needle bearing bushing. 23. First gear needle bearing. 24. First gear. 25. First gear thrust washer. 26. Output shaft bearing. 27. Output shaft bearing snap ring. 28. Fifth gear. 29. Bushing. 30. Output shaft rear bearing. 31. Output shaft snap ring.

1–8. Output shaft disassembly

1. Remove the fifth gear, the output shaft bearing, the first gear thrust washer and the first gear from the output shaft.

Fig. 57. Removal of the fifth gear and bearing

2. Remove the first gear synchroniser ring, the first gear needle bearing and the first gear needle bearing bushing.

3. Remove the first gear synchroniser hub snap ring using two screwdrivers.

Removal of the synchroniser hub snap ring — Fig. 59. Removal of the first gear synchroniser hub snap ring

4. Remove the first/second synchroniser, the second gear synchroniser ring, the second gear and the second gear needle bearing.

Fig. 60. Removal of the first/second synchroniser

5. Disassemble the first/second synchroniser.

Fig. 61. Disassembly of the first/second synchroniser

6. Remove the second gear synchroniser hub snap ring.

Fig. 62. Removal of the second gear synchroniser hub snap ring

7. Remove the third/fourth synchroniser, the third gear synchroniser ring, the third gear and the third gear needle bearing.

Fig. 63. Removal of the third/fourth synchroniser

8. Disassemble the third/fourth synchroniser.

Fig. 64. Disassembly of the third/fourth synchroniser

Output shaft component inspection

1–4. Clearance checks

1. Measure the clearance between the synchroniser ring and the gear using a feeler gauge.

Fig. 65. Measuring the clearance between the synchroniser ring and gear

Clearance values:

First gear: 1.2 ± 0.55 mm
Second gear: 1.2 ± 0.55 mm
Third gear: 1.2 ± 0.45 mm

2. Try to turn and press the synchroniser ring to check its operation.

3. Check the clearance between the first gear shift fork and the first gear synchroniser sleeve.

Checking the clearance between the first gear fork and sleeve — Fig. 67. Checking the clearance between the first gear fork and synchroniser sleeve

Measure the slot size of the first gear shift fork using a calliper. Standard value: 5.28 mm.
Measure the protrusion size of the first gear synchroniser sleeve using a calliper. Standard value: 5.00 mm.
Calculate the clearance between the first gear shift fork and the first gear synchroniser sleeve. Standard value: 0.28 mm.

4. Check the clearance between the second gear shift fork and the second gear synchroniser sleeve.

Checking the clearance between the second gear fork and sleeve — Fig. 68. Checking the clearance between the second gear fork and synchroniser sleeve

Measure the protrusion size of the second gear shift fork using a calliper. Standard value: 10.00 mm.
Measure the slot size of the second gear synchroniser sleeve using a calliper. Standard value: 10.2 mm.
Calculate the clearance between the second gear shift fork and the second gear synchroniser sleeve. Standard value: 0.20 mm.

5. Output shaft technical condition check

1. Measure the outer diameter of each output shaft gear using a micrometer.

Measuring the outer diameter of the gears — Fig. 69. Measuring the outer diameter of the output shaft gears

Gear	Value, mm
A	38.000
B	47.000
C	38.987

2. Measure the output shaft flange width using a micrometer. Standard value: 5.0 mm.

Fig. 70. Measuring the output shaft flange width

3. Measure the output shaft radial runout using a dial indicator.

Standard value: less than 0.015 mm.

Fig. 71. Measuring the output shaft radial runout

4. Measure the inner diameter of each output shaft gear using a bore gauge.

Measuring the inner diameter of the gears — Fig. 72. Measuring the inner diameter of the output shaft gears

Gear	Value, mm
First gear	46.0275
Second gear	53.0275
Third gear	44.0275

Output shaft assembly

1–6. Assembling the synchronisers and installing the third gear

1. Assemble the first/second synchroniser.

First install the three springs and then press the springs into the synchroniser keys using a screwdriver or another suitable tool.

Fig. 73. Pressing the springs into the synchroniser keys

Install the first gear synchroniser sleeve.

Note: the first/second synchroniser has identification marks on surfaces "a" and "b".

Fig. 74. Installing the first gear synchroniser sleeve

2. Assemble the third/fourth synchroniser. To do this, install the synchroniser hub, the synchroniser key and the expander ring on the synchroniser sleeve.

Note: the third/fourth synchroniser has identification marks on surfaces "a" and "b".

Fig. 75. Assembling the third/fourth synchroniser

3. Install the third gear and the third/fourth synchroniser on the output shaft.

Apply a thin layer of clean transmission oil to the shaft and the third gear needle bearing.
Place the synchroniser ring on the third gear and align the synchroniser ring slot hole with the synchroniser key.

Fig. 76. Aligning the synchroniser ring with the key

Install the needle bearing into the third gear.

4. Press the third/fourth synchroniser onto the output shaft.

Fig. 77. Pressing the third/fourth synchroniser onto the output shaft

5. Select the output shaft snap ring.

Note: select the output shaft snap ring so that the axial clearance is less than 0.1 mm.

Fig. 78. Selecting the output shaft snap ring

6. Install the output shaft snap ring.

Fig. 79. Installing the output shaft snap ring

7. Measure the third gear axial clearance using a feeler gauge.

Standard value: 0.175 mm.

Fig. 80. Measuring the third gear axial clearance

8–12. Installing the second and first gears

8. Install the first gear and the first/second synchroniser.

Apply a thin layer of clean transmission oil to the shaft and the second gear needle bearing.
Place the second gear synchroniser ring on the second gear and align the three intermediate ring protrusions with the three gear slots.

Fig. 81. Aligning the synchroniser ring with the second gear

Install the second gear needle bearing and the second gear.

Fig. 82. Installing the needle bearing and second gear

Install the first/second synchroniser.

Note: be careful not to mix up the installation direction of the first/second synchroniser.

Fig. 83. Installing the first/second synchroniser

9. Select the output shaft snap ring.

Note: select the output shaft snap ring so that the axial clearance is less than 0.1 mm.

10. Install the output shaft snap ring using a screwdriver.

11. Measure the second gear axial clearance using a feeler gauge.

Standard value: 0.175 mm.

Fig. 86. Measuring the second gear axial clearance

12. Install the first gear. To do this, install the first gear needle bearing bushing, the first gear needle bearing, the first gear synchroniser ring and the first gear in the order shown in the figure.

Note: apply a thin layer of clean transmission oil to the output shaft, the needle bearing and the conical surface of the first gear before aligning the three intermediate ring protrusions of the first gear synchroniser with the gear slots.

13–17. Installing the thrust washer, bearing and fifth gear

13. Install the first gear thrust washer. To do this, install the pin and the thrust washer on the output shaft.

Note: make sure the pin is installed correctly.

Fig. 88. Installing the first gear thrust washer

14. Install the output shaft bearing.

The side of the output shaft bearing with the snap ring groove must face rearwards.

Lift the first gear thrust washer with a screwdriver or another suitable tool while pressing on the output shaft bearing to prevent it from falling out.

Fig. 89. Installing the output shaft bearing

15. Measure the first gear axial clearance using a feeler gauge. Standard value: 0.325 mm.

Fig. 90. Measuring the first gear axial clearance

16. Install the fifth gear on the output shaft.

Fig. 91. Installing the fifth gear on the output shaft

17. Measure the radial clearance of the output shaft gears using a dial indicator.

Fig. 92. Measuring the radial clearance of the output shaft gears

Gear	Value, mm
First gear	0.265
Second gear	0.265
Third gear	0.265

Intermediate shaft

Intermediate shaft disassembly

1. Remove the front intermediate shaft bearing snap ring.

Fig. 94. Removal of the front intermediate shaft bearing snap ring

2. Remove the front intermediate shaft bearing.

Fig. 95. Removal of the front intermediate shaft bearing

Intermediate shaft assembly

1. Measure the diameters of the rear bearing and the fifth gear of the intermediate shaft.

Fig. 96. Measuring the diameters of the rear bearing and fifth gear

Measurement point	Value, mm
A	34.00
B	30.00

2. Install the front intermediate shaft bearing. Note: make sure the bearing side with the groove faces downwards.

Fig. 97. Installing the front intermediate shaft bearing

3. Select the intermediate shaft snap ring.

Note: select the intermediate shaft snap ring so that the axial clearance is less than 0.1 mm.

Fig. 98. Selecting the intermediate shaft snap ring

4. Install the intermediate shaft snap ring.

Fig. 99. Installing the intermediate shaft snap ring

Front cover

Front cover disassembly

Remove the T-section oil seal from the front cover.

Fig. 101. Removal of the T-section oil seal from the front cover

Front cover assembly

Install the T-section oil seal of the front cover.

Note: apply a thin layer of clean transmission oil to the outer surface of the T-section oil seal lip.

Fig. 102. Installing the T-section oil seal of the front cover

Rear gearbox case

Rear gearbox case disassembly

1. Remove the shift shaft and shift block from the rear gearbox case.

Fig. 103. Removal of the shift shaft and shift block

2. Remove the rear gearbox case boot using a special tool.

Removal of the rear case boot — Fig. 104. Removal of the rear gearbox case boot

3. Loosen the threaded plug using a special tool.

4. Remove the elastic cylindrical pin and extract the reverse gear lock mechanism using a special tool.

Fig. 106. Extraction of the reverse gear lock mechanism

5. Loosen the threaded plug using a special tool.

Loosening the second threaded plug — Fig. 107. Loosening the threaded plug

6. Loosen the hex head bolt with washer and remove the lubrication guide.

Fig. 108. Removal of the lubrication guide

7. Remove the rear gearbox case oil seal using a special tool.

Removal of the rear case oil seal — Fig. 109. Removal of the rear gearbox case oil seal

Rear gearbox case assembly

1. Install the lubrication guide and secure it with the hex head bolt with washer, then install the lubrication guide nozzle.

Fig. 110. Installing the lubrication guide

2. Screw in the threaded plug using a special tool.

3. Install the reverse gear lock mechanism.

Install the reverse gear lock mechanism into the bore.

Fig. 112. Installing the reverse gear lock mechanism

Install the elastic cylindrical pin.

Fig. 113. Installing the elastic cylindrical pin

4. Screw in the threaded plug using a special tool.

Screwing in the second threaded plug — Fig. 114. Screwing in the threaded plug

5. Install the rear gearbox case oil seal.

Note: the clearance between the installed oil seal surface and the rear gearbox case surface must be 0 ± 0.05 mm.

Installing the rear case oil seal — Fig. 115. Installing the rear gearbox case oil seal

6. Install the rear gearbox case boot using a special tool.

Installing the rear case boot — Fig. 116. Installing the rear gearbox case boot

Intermediate plate

Intermediate plate disassembly

Note: the intermediate plate disassembly operations are described at the beginning of the article «Removal of the shift components».

Intermediate plate assembly

1. Secure the intermediate plate in a vice.

2. Install the output shaft onto the intermediate plate.

Fig. 118. Installing the output shaft onto the intermediate plate

3. Install the output shaft snap ring.

4. Install the bushing onto the output shaft.

Fig. 120. Installing the bushing onto the output shaft

5. Install the output shaft rear bearing.

Fig. 121. Installing the output shaft rear bearing

6. Select the output shaft snap ring.

Note: select the output shaft snap ring so that the axial clearance is less than 0.1 mm.

7. Install the output shaft snap ring using a screwdriver.

8. Install the input shaft.

Install the input shaft onto the output shaft while turning the input shaft.
Make sure the synchroniser ring slot is aligned with the synchroniser key.

Fig. 124. Installing the input shaft onto the output shaft

9. Install the intermediate shaft into the gearbox intermediate plate.

Fig. 125. Installing the intermediate shaft into the intermediate plate

10. Install the intermediate shaft rear bearing.

Note: the snap ring is built into the intermediate shaft rear bearing.

Fig. 126. Installing the intermediate shaft rear bearing

11. Install the reverse intermediate gear and the reverse intermediate gear shaft onto the gearbox intermediate plate.

Note: the side with the groove of the reverse intermediate gear must face rearwards.

Fig. 127. Installing the reverse intermediate gear and shaft

12. Install the output shaft rear bearing baffle and secure it with the mounting bolts. Tighten the bolts to the recommended torque using a torque wrench. Tightening torque: 12.6–23.4 N·m.

Installing the rear bearing baffle — Fig. 128. Installing the output shaft rear bearing baffle

13. Install the fifth gear thrust washer.

Install the pin into the intermediate shaft pin bore.
Install the fifth gear thrust washer.

Note: be careful not to mix up the installation direction of the thrust washer.

Fig. 129. Installing the fifth gear thrust washer

14. Install the intermediate shaft fifth gear.

Install the third gear synchroniser sleeve.
Install the third gear synchroniser key, the synchroniser expander ring, the synchroniser spring and the intermediate shaft snap ring.

Fig. 130. Installing the third gear synchroniser sleeve and key

Install the intermediate shaft fifth gear needle bearing, the intermediate shaft fifth gear and the fifth gear synchroniser gear ring.

Fig. 131. Installing the needle bearing and fifth gear

15. Engage the fifth gear.

16. Measure the fifth gear axial clearance using a feeler gauge. Standard value: 0.225 mm.

Fig. 133. Measuring the fifth gear axial clearance

17. Select the intermediate shaft snap ring.

Note: select the intermediate shaft snap ring so that the axial clearance is less than 0.1 mm.

18. Install the intermediate shaft snap ring using a screwdriver.

19. Install the reverse rocker bracket and secure it with the mounting bolts. Tighten the bolts to the recommended torque using a torque wrench. Tightening torque: 12.6–23.4 N·m.

Fig. 136. Installing the reverse rocker bracket

20. Connect the reverse rocker to the reverse shift fork. Install the E-clip using a screwdriver to secure the reverse rocker and the reverse shift fork.

Securing the rocker and fork with the E-clip — Fig. 137. Securing the reverse rocker and fork with the E-clip

21. Install the reverse rocker and reverse shift fork assembly into their mounting position.

Fig. 138. Installing the reverse rocker and fork assembly

22. Install the steel ball and spring into the reverse rocker.

Installing the ball and spring into the rocker — Fig. 139. Installing the steel ball and spring

23. Install the reverse shift fork shaft.

Installing the reverse fork shaft — Fig. 140. Installing the reverse shift fork shaft

24. Install the steel ball and the shift lock guide rod.

Install the steel ball into the reverse rocker.
Install the shift lock guide rod into the gearbox intermediate plate and install the steel ball into the reverse shift fork shaft.

Installing the ball and lock guide rod — Fig. 141. Installing the steel ball and shift lock guide rod

25. Install the third gear shift fork and the third gear shift fork shaft.

Installing the third gear fork and shaft — Fig. 142. Installing the third gear shift fork and shaft

26. Install the reverse shift fork shaft snap ring and the third gear shift fork shaft snap ring using a screwdriver.

Fig. 143. Installing the fork shaft snap rings

27. Install the shift lock guide rod into the gearbox intermediate plate.

Fig. 144. Installing the shift lock guide rod

28. Install the first gear shift fork and the first gear shift fork shaft.

Apply a thin layer of clean transmission oil inside the pin bore of the first gear shift fork shaft and install the short shift lock pin inside the shift fork shaft.
Then insert the first gear shift fork shaft into the first gear shift fork through the gearbox intermediate plate.

Note: be careful not to mix up the installation direction of the first gear shift fork. Be careful not to drop the short shift lock pin.

Installing the first gear fork and shaft — Fig. 145. Installing the first gear shift fork and shaft

29. Install the shift lock guide rod into the gearbox intermediate plate.

30. Install the second gear shift fork and the second gear shift fork shaft.

Note: the second gear shift fork shaft must be installed through the gearbox intermediate plate bore, the first gear shift fork bore and the second gear shift fork bore. Be careful not to mix up the installation direction of the second gear shift fork.

Installing the second gear fork and shaft — Fig. 147. Installing the second gear shift fork and shaft

31. Secure the third gear shift fork and the third gear shift fork shaft with the elastic cylindrical pin, installing it using a special tool.

Securing the third gear fork with the pin — Fig. 148. Securing the third gear fork and shaft with the elastic cylindrical pin

32. Install the first gear shift fork shaft snap ring and the second gear shift fork shaft snap ring using a screwdriver.

33. Secure the first gear shift fork and the second gear shift fork with the mounting bolts. Tighten the bolts to the recommended torque using a torque wrench. Tightening torque: 15.6–23.4 N·m.

34. Install the steel balls, springs and screw in the threaded plugs.