Lubricate all parts before assembly.
Note:
- This gearbox does not use a gasket between the clutch and gearbox, but uses a liquid sealant.
- Always clean the magnet (item 66) when disassembling the gearbox.
- Check all bearings for wear and smooth operation.
Tightening torque
- A - 15 Nm (1,5 kgf·m.11lbf·ft)
- B - 27 Nm (2,8 kgf·m. 20lbf·ft)
- C - 31 Nm (3-2 kgf·m. 23lbf·ft)
1. Ball bearing.
2. Fifth gear synchronizer hub.
3. Fifth gear synchronizer clutch.
4. Fifth gear synchronizer spring.
5. Fifth gear synchronizer retaining ring.
6. Fifth gear.
7. Needle bearing 32x37x23.5.
8. Inner race of bearings of gears of 4th and 5th gears.
9. Needle bearing 34x39x23.
10. Fourth gear.
11. Synchronizer retaining ring.
12. Synchronizer spring,
13. 3rd/4th gear synchronizer clutch.
14. 3rd/4th gear synchronizer hub.
15. Third gear pinion.
16. Needle bearing 34x39x27.5.
17. Primary shaft.
18. Washer.
19. Spring washer.
20. Ball bearing.
21. Seal.
22. Cork 28mm.
23. Spring
24. Gear selector lever shaft.
25. Clutch housing.
26. Lock guide bolt (39 Nm).
27. Reverse gear lock.
28. Reverse intermediate gear.
29. Reverse intermediate gear shaft.
30. Spring pin (replace).
31. 3rd and 4th gear shift head.
32. 5th gear and reverse gear shift head.
33. MBS shift head.
34. 1st and 2nd gear shift fork.
35, 3rd and 4th gear shift fork.
36. 5th gear and reverse gear shift fork.
37. Retaining ring 52 mm.
38. Axial pressure adjusting shim.65mm (*1).
Axial pressure adjustment shim.70mm (*2).
39. Oil guide plate.
40. Washer.
41. Reverse light switch.
42. Set screw.
43. Washer.
44. Spring 31.6 mm.
45. Steel ball.
46. Reverse light switch harness stand.
47. Gearbox bracket.
48. Sealing bolt 32 mm 25 Nm.
49. Seal
50. Drain plug 39 Nm.
51. Washer.
52. Oil filler plug.
53. Washer.
54. Gearbox housing.
55. Exhaust pipe stand.
56. Oil gutter.
57. Reverse gear lock cam.
58. Reverse gear selection spring.
59. Reverse gear lock.
60. Gear selector lever C.
61. Gear selector lever B.
62. Castle.
63. Bushing.
64. Gear selector lever A.
65. Spring washer.
66. Magnet.
67. Ball spring adjusting bolt 22 Nm.
68. Mounting pin 14x20 mm.
69. Axial pressure adjusting washer 72 mm. Axial pressure adjusting washer 80 mm.
70. Differential assembly.
71. Oil seal 14x25x17.5 mm.
72. Oil seal 35x56x8 mm.
73. Gear shift rod.
74. Cover.
75. Oil guide plate.
76. Needle bearing (*1) 30x47x21 mm. Needle bearing (*2) 30x55x21 mm.
77. Intermediate shaft.
78. Needle bearing 36x41x25.5 mm.
79. First gear pinion.
80. Friction shock absorber.
81. Synchronizer ring.
82. Synchronizer spring.
83. 1st and 2nd gear synchronizer hub.
84. Reverse gear.
85. Synchronizer spring.
86. Synchronizer ring.
87. Friction shock absorber.
88. Inner bearing race.
89. Needle bearing 39x44x27 mm.
90. 2nd gear pinion.
91. 3rd gear pinion.
92. 4th gear pinion.
93. 5th gear pinion.
94. Ball bearing (*1) Needle bearing (*2).
95. Ball bearing.
96. Spring washer.
97. Lock nut 108-0-108 Nm.
*1: engines D14A3, D14A4, D15Z4, D15Z5, D16Y7;
*2: engines D15Z6, D15Z7, D16Y5, D16Y8, D16Y9,