Disassembling the gearbox to replace parts
Before disassembling the gearbox, we wash it and install it on the rack
Remove the gearbox upper support bracket
Remove the shift cable bracket
Remove the clutch release cylinder
Remove the reverse light switch
Remove the speedometer drive mechanism
Remove the clutch release fork shaft and support sleeve
Unscrew the expander mounting bolt
Remove the ball poppet assembly
Remove the side cover and intermediate gear
Remove the selector lever, shift lever and seal cover
Remove the clutch housing from the gearbox housing with an expansion spring ring
Remove the lock housing and control shaft
Remove the shift shaft
Remove the fifth gear fork
Remove the third and fourth shift fork
Remove the first and second shift fork
Remove the bearing holder
Simultaneously remove the input and driven shaft
Removing the differential
Remove the retainer cover and roller bearing
Using puller 09455-33200, remove the outer differential bearing spacer and drive shaft oil seal
Remove the shift and gear selector levers from the gearbox housing
Assembly
Using a suitable mandrel or special mandrel 09455-33200, set driveshaft seal
Install the shift and gear levers in the gearbox housing
Installing the retainer cover and needle bearing
Installing the differential
At the same time, we install the input and driven shaft
Installing the holder bearing
Installing the first and second shift fork
Installing the third and fourth shift fork
Installing the fifth gear fork
Installing the shift shaft
Installing the lock housing and control shaft
We assemble the clutch housing with the gearbox housing with an expansion spring ring
Installing the selector lever, shift lever and seal cover
Installing the side cover and intermediate gear
Installing the ball poppet valve assembly
We screw in the expander fastening bolt
Installing the release fork shaft is coupled and support sleeve
Installing the speedometer drive mechanism
Installing the reverse light switch
Installing the clutch release cylinder
Installing the shift cable bracket
Installing the gearbox upper support bracket