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Removing
Removing
–  Position catch pan underneath.
   
–  Drain gear oil, to this end unscrew oil drain plug -arrow-.
  S34-0156
–  Secure gearbox to the assembly stand -arrows-.
–  Removing the release lever, release bearing and guide bushing → Chapter.
–  Unscrew the cover -1- for the gearbox housing.
  S34-0310
Remove shift fork and 5th gear sliding sleeve as follows:
–  Put shift fork -1- in Neutral position.
–  Release screw -2- for bearing pins.
–  Remove bearing pins -arrows A-.
–  Guide shift fork out of shift rail -arrow B-.
–  Remove spring -3-.
–  Carefully pull off sliding sleeve -4-, and also remove locking elements.
–  Put the sliding sleeve without shift fork back onto the synchronizer body.
  S34-0511
–  Unscrew screws -A- for synchronizer body and 5th gear pinion. To this end engage the 5th gear -arrow 1- and 1st gear -arrows 2 and 3-.
–  The input and output shafts are blocked after introducing the two gears, the synchronizer body and pinion cannot rotate. Now it is possible to release the two bolts.
–  Pull off 5th gear synchronizer, sliding sleeve and arresters with extractor -T10309-.
  N34-0927
–  Insert device -T10309/1- between 5th gear pinion -A- and bearings of the shift fork for 5th gear -B-.
Device -T10309/1- must be positioned under the synchronizer ring and if necessary pressed into the end position.
–  Turn device -T10309/1--in direction of arrow-.
  N34-10584
–  Fit the extension onto the device -T10309/1- with thread -T10309/3-.
–  Position the other device -T10309/1- and fit pipe -T10309/2- above both devices.
–  After drawing together, check if the synchronizer body is not damaged.
–  Remove 5th gear pinion together with needle bearing of the drive shaft.
  N34-10585
–  Remove gearwheel for 5th gear.
  Note
t  When pulling off the gear pinion make sure the hooks do not bend outwards, if necessary tighten screw -arrow-.
t  5. Check 5th gear for damage after removing.
A - Two-arm extractor e. g. -Kukko 20/10- with hook -Matra V/170-
B - Hexagon screw M10 x 20
Mounting sequence:
t  Set up two-arm extractor and centre by turning the screw -arrow-.
t  If necessary heat pinion with hot-air blower (e.g. -V.A.G 1416-) and remove with two-arm extractor.
  S34-0524
–  Remove the left flange shaft. Use drift to secure against turning and unscrew conical screw -arrow-.
  N34-0109
–  Remove both screws -arrows- for support/reverse shaft.
–  Remove the gearshift shaft with cover. Put the gearshift shaft into Neutral.
  V34-2007
–  Subsequently unscrew screws -arrows- and remove the gearshift shaft from the gearbox housing by levering off the gearshift cover.
  N34-0928
–  Remove screws -arrows- from the cap -A- and the bearing pins -B- at the bottom of the gearbox.
  S34-0500
–  Carefully remove the cap -A- with driver -MP 1-304 - and hammer -B-.
  S34-0523
–  Remove bearing pins -A- on the top side of the gearbox and fixing screws -B- for the gearbox housing on the clutch housing near the differential gear.
  V34-2615
–  Release screws -A-, that serve to secure the gearbox housing from the clutch housing.
  Note
Do not release nuts -B- for the output shaft bearing support.
  S34-0135
–  Carefully release the gearbox housing from the projecting housing lands -arrows- and make sure the sealing surfaces are not damaged in the process.
  V34-2618
–  Remove shift forks -A- together with shift rails.
–  Unscrew shift mechanism/reverse gear -B-.
  V34-2619
–  Release nuts -B- for the bearing support/output shaft.
  S34-0135
–  Successively remove the reverse gear -A-, drive shaft -B- and output shaft -C- from the clutch housing.
–  Remove right flange shaft and take out differential gear.
  V34-2620

Power transmission > Gearbox 02R > Gearbox mechanics,operation, construction,diff. > Disassembling and assembling the gearbox > Mounting sequence > Removing

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