To dismantle

Observe the following before dismantling the gearbox:

Fig 1: Identifying Gearbox

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• clean the gearbox

  After cleaning the outside of the gearbox, start work as follows:

  IMPORTANT: The openings for the drive shafts and the delivery line to the slave cylinder must be covered before cleaning the gearbox. Plug for drive shaft, part no. 87 92 665.
  Fig 2: Illustration For Step 1

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1. Place the gearbox in a work stand with 87 92 228 HOLDER, TRANSMISSION  .
2. Detach the delivery line. Compress the sleeve on the inside using pliers and push the delivery line forward. Pry up the catch on the sleeve and press in the delivery pipe to detach it.
   Fig 3: Illustration For Step 2

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3. Undo the slave cylinder screws and remove it.
4. Unscrew the reverse shaft. Note the O-ring.
5. Unscrew the end cover. Remove the cover and the gasket.
   Fig 4: Illustration For Step 5

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6. Engage 1st gear to secure the gearbox and prevent the selector mechanism detent balls from coming out. Tap out the retention pin for the 5th gear selector fork.
   Fig 5: Illustration For Step 6

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   IMPORTANT: Before removing the synchromesh sleeve, mark its position relative to the 5th gear synchromesh with a pen to facilitate refitting.

   Remove the fork and synchromesh sleeve and then refit the synchromesh sleeve.

7. Press down the synchromesh sleeve so that 5th gear is engaged. Two gears must be engaged simultaneously when the nut on the output shaft is unscrewed.
   Fig 6: Illustration For Steps 7-8

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   Note that the synchromesh sleeve may only be placed on the synchromesh hub when the high lugs on the sleeve are opposite the tooth gaps on the synchromesh hub that are opposite the deep tooth gaps.

8. Tap off the lock on the output shaft nut using a drift.

   Remove the nut.

   IMPORTANT: In all work which involves dismantling the gearbox, a new nut and a new clamping sleeve should be fitted on assembly as the old clamping sleeve will have lost its tension.
9. Remove the circlip for 5th gear synchromesh hub. This is made easier by first carefully tapping down the hub.
   Fig 7: Illustration For Step 9

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   Lift off the synchromesh sleeve. Then use 87 91 287 PULLER, 150 MM  , 87 91 303 ARM, 150 MM  and 87 92 640 TOOL, 5TH GEAR SYNCHROMESH HUB  to lift off 5th gear's synchromesh hub (use grease on the tip of the puller). Keep the leaf springs in a safe place. Then lift up the pinion, baulk ring and needle bearing.

10. Remove 5th gear's gear wheel with 89 96 084 PULLER, WHEEL HUB  , 87 92 566 PULLER, 5TH GEAR PINION  and 87 91 410 SLEEVE 
    Fig 8: Illustration For Step 10

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11. Undo the screws for the differential seal retainer.
    Fig 9: Illustration For Steps 11-14

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12. Remove the seal retainer and keep the shims.
13. Undo the screw for the reverse shaft support in the gear case.
14. Undo and remove the bolts from the mating surface between the gear case and the clutch housing. Tap down the 2 locating sleeves.
15. Check that a gear is engaged. This prevents the input and output shafts from coming along out. Screw in two 87 92 129 ATTACHMENT EYE, PULLER (X 2)  . 87 91 410 SLEEVE  is fitted on the output stub axle. Hook on 87 91 287 PULLER, 150 MM  with 87 91 303 ARM, 150 MM  in the tools and carefully pull off the housing until the pinion and bearing release from the shaft. Tap carefully to loosen the mating surface.
    Fig 10: Illustration For Step 15

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16. Remove tools. Lift off the gear case.
17. Knock out the differential bearing race. Use 87 92 202 SLEEVE  , 87 91 204 SLEEVE, BEARING RACE  and 87 91 410 SLEEVE 
    Fig 11: Illustration For Step 17

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18. Remove shaft and selector fork for reverse.
    Fig 12: Illustration For Step 18

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19. Unscrew and remove the reverse gear selector fork.
    Fig 13: Illustration For Step 19

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20. Engage reverse gear on the selector mechanism to gain access to the screw for the selector rod.
    Fig 14: Illustration For Step 21

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21. Remove the screw for the driver on the selector rod. Withdraw the shaft and keep the driver.
22. Disengage reverse. Remove the screw and lift the selector mechanism slightly to lift the locating sleeves from their seats. Lift off the sleeves.
    Fig 15: Illustration For Step 22

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    Pull the selector mechanism back towards the differential and angle it out slightly. Lift out the selector mechanism.

23. Lift the input shaft slightly and lift the reverse shaft and pinion (reverse gear).
    Fig 16: Illustration For Step 23

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24. Lift off the 4th gear wheel, leaving the collet and spacer sleeve in place on the shaft.
    Fig 17: Illustration For Step 24

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25. Place 87 91 287 PULLER, 150 MM  with 87 91 295 ARM, 300 MM  under 1st gear's wheel on the output shaft. Lift up the drive assembly with two screwdrivers so that the shanks go in under 1st gear's pinion. Place 87 91 410 SLEEVE  on the output shaft as protection. Tighten slightly and fit 87 92 103 ASSEMBLY FIXTURE, 1ST AND 2ND GEAR HUBS  which holds together 1st and 2nd gears' synchromesh assembly. Attach a cable tie around the tool and pinion assembly. Pull up all gear wheels of the output shaft about 15 mm.
    Fig 18: Illustration For Steps 25-26

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26. Lift out the input shaft.
27. Tighten until the gear wheels on the output shaft become detached.
    Fig 19: Lifting Off Gear Wheels Gear Puller

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28. Lift off the gear wheels (1st, 2nd and 3rd gears) and the baulk rings and synchromesh sleeves which are held together by 87 92 103 ASSEMBLY FIXTURE, 1ST AND 2ND GEAR HUBS 
29. Undo 4 bolts and remove the output shaft bearing support.
    Fig 20: Illustration For Step 29

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    NOTE: Assist the removal of the bolts by heating the gear case so that the threadlocker breaks. Tapping with a center punch will also assist in removing the bolts.
30. Pull up the output shaft. Use 87 91 188 SUPPORT, FOR REMOVING PINION SHAFT  , 87 91 972 RING  and 87 91 261 PULLER, PINION  .
    Fig 21: Illustration For Steps 30-31

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31. Lift out the differential.