To dismantle

Observe the following before dismantling the gearbox:

Fig 1: Identifying Gearbox

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• remove the reversing-light switch to prevent it being damaged and cover the hole left by the switch.
• clean the gearbox
  IMPORTANT: The holes for the drive shafts and the feed line to the slave cylinder should be covered before the gearbox is to be cleaned, use plugs for the drive shaft holes 587 92 665.

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

  Fig 2: Illustration For Step 1

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1. Position 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 bolts 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 that 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 securing the 5th gear synchromesh hub. This is made easier by first carefully tapping down the hub. Lift off the synchromesh sleeve and 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 the 5th gear's synchromesh hub (grease the puller's tip). Save the leaf springs. Then lift up the pinion, baulk ring and needle bearing.
   Fig 7: Illustration For Step 9

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10. Remove the gear wheel for 5th gear with 87 92 566 PULLER  .

    89 96 084 PULLER, WHEEL HUB  and 87 91 410 SLEEVE  .

    Fig 8: Illustration For Step 10

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11. Undo the bolts 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 bolt for the reverse shaft support in the gearcase.
14. Undo and remove the bolts from the mating surface between the gearcase and the clutch housing. Tap down the 2 locating sleeves.
15. Check that 3rd or 4th gear is engaged. Screw in the two 87 92 129 ATTACHMENT EYE, PULLER (X2)  . Fit 87 91 410 SLEEVE  on the end of the output shaft. Hook 87 91 287 PULLER, 150 MM  with 87 91 303 ARM, 150 MM  into the eyes and carefully pull out the casing until pinion and bearing come off the shaft. Tap carefully so that the mating faces separate.
    Fig 10: Illustration For Step 15

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16. Remove tools. Lift off the gearcase.
17. Tap out the differential bearing race. Use 87 92 202 SLEEVE  and 87 91 204 SLEEVE, BEARING RACE  .
    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 bolt for the selector rod.
    Fig 14: Illustration For Step 21

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21. Remove the bolt for the driver on the selector rod. Withdraw the shaft and keep the driver.
22. Disengage reverse. Remove the bolt 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; leave the clamping sleeve and spacer sleeve on the shaft.
    Fig 17: Illustration For Step 24

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25. Fit 87 91 287 PULLER, 150 MM  with 87 91 303 ARM, 150 MM  under the 1st gear wheel on the output shaft. Fit 87 91 410 SLEEVE  to protect the end of the output shaft. Pull slightly and fit 87 92 103 ASSEMBLY FIXTURE, 1  to hold the 1st and 2nd gear synchromesh assembly together. Fit a cable tie round the tools and drive assembly. Pull up all gears about 15 mm on the output shaft.
    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: Removing Input Shaft

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28. Lift off the gear wheels (for 1st, 2nd and 3rd gear) as well as baulk rings and synchromesh sleeve, all held together by 87 92 103 ASSEMBLY FIXTURE 
29. Remove 4 bolts and remove the output shaft bearing support. Tap with a drift to easier release the bolts if needed.
    Fig 20: Illustration For Step 29

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30. Pull up the output shaft. Use 87 91 188 SUPPORT, REMOVAL OF 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.