Disassembly and repair of the gearbox

To order spare parts, please state the gearbox number stamped on the rear cover. The last three digits of the number indicate the gear ratio of the final drive (e.g. 394 = 3,94). Before starting the actual disassembly, the gearbox should be removed and secured to a suitable stand. When assembling the gearbox, all seals must be replaced.

Removing and disassembling the cover of the internal gear shift

■ Remove the gearbox bleed screw

■ Remove the bolts securing the cover of the internal gear shift.

■ Attach the removed cover to the pedestal with the outer side down.

■ Remove from the guide pin: locking ring, sleeve, the spring and the intermediate gearshift lever.

■ Use the mandrel to drive the expansion pin out of the control rod and selector.

■ Pull out the control stick

■ The cover is supplied as a spare part complete with a guide pin.

■ Remove the joint rivet of the rubber track stick, grinding the rivet head

■ Remove the gasket from the cover.

■ Remove the bolt of the speedometer drive mounting plate. Leveraging with a screwdriver, remove the drive body and the end with a toothed wheel.

■ Unscrew the reverse light switch, be careful of any leaking oil.

Removing and disassembling the rear cover

■ If the gearbox has not been removed from the car, then you should lower the engine at the back, so that the trestle does not obstruct the cover. To do this, the engine must be suspended and the front left engine suspension unscrewed (at the joystick) and middle ones (at the crossbar). Do not jam the clutch release lever when lowering the engine.

■ Push the rear fork forward with a screwdriver, including this way

2. run.

■ Remove the screws securing the rear cover.

■ Remove the rear cover together with the main and drive shafts from the gearbox housing.

■ Place the cover on a suitable stand.

■ Knock out three hole plugs, with pins for locating the sliders. Remove the springs and pins from the holes.

■ Put the shifter in neutral and remove the forks and the slides for 3. and 4 running.

■ Remove the circlips, securing the main and drive shafts.

■ Remove the main and drive shafts, reverse gear and forks and sliders for 1. and 2. running.

■ Remove two bolts from the holes in the cover, which do not allow two gears to be engaged at the same time.

■ Place the reverse gear shaft in a vice (with shrouds on the jaws) and knock out the cover, using the brass mallet carefully Pay attention to the securing ball.

Demolition of the main roller

■ Use a suitable pin to press the main shaft out of the gear train.

■ Remove the circlip and washer in front of the bearing. then use a suitable tube to press the bearing out of the gear assembly.

If the teeth in the gear train are damaged, the corresponding gear on the drive shaft must also be replaced.

Demolition of the drive shaft

w Unscrew the fork from the clutch release lever, and from the gearbox housing the guide bushing is the release bearing.

■ Press the needle bearing race out of the gearbox housing, supporting the main shaft.

■ Using a puller with support, pull out the coiled sleeve of the drive shaft.