(A) Disassembly
Fasten gearbox onto support No. 7002.

Remove gearshift lug from gearshift arm.

Only if torsion spring is defective:
Remove catch plate together with torsion spring and
spring.

Assembly position of torsion spring and spring.

Fit in catch plate together with torsion spring.
The long stud must face towards the torsion spring.

Fit in spring with the long side facing towards the tor-
sion spring.

Take off gearshift arm.

Take off vibration damper.

Slide off guide piece.

Detach guide flange¹).
Check guide sleeve for wear.


¹) See Technical Data

Note! Shims.

Lift out circlips.
Note! Shims.

Extract ball bearing - Rillex 6306 long -
Note: Shims.

Remove bearing pin 3rd and 4th gear.

Detach front of housing.

Fitting instruction: use grease when inserting pressure
spring and slide piece.

Extract shift rails for 3rd and 4th and 1st and 2nd gears
forwards.

Extract shift rail for reverse gear to the rear.
Fitting instruction: deep shift rod cutout should be towards
shift lever side.

Engage 1st gear.
Remove selector fork 3rd and 4th gears.

Lift out locking plate.
Fitting instruction: Chisel locking plate over into drive
flange groove.

Unscrew flanged nut - retaining spanner 604.
Pull off drive flange.

Detach cover.
Note! Shims.

Pull off speedometer pinion and washer.

Pull off ball bearing from layshaft Rillex 6305.

Remove main shaft and layshaft with roller assembly and
synchromesh unit.
Important: Mark synchronizing ring for gear wheel.

Replace the gears for 3rd and 4th
Pull off circlip.
Pull off ball bearing.
Press off gear for 4th gear.
Pull off circlip.
Press off gear for 3rd gear.
Pressure for removal: approx. 5,000 kp.
Note when assembling: Use C 3 bearings only.
Heat gears to 150°-180° C (302-356° F).

Compensate play between ball bearing and circlip by
using shims.

Engage 2nd gear.
Remove bearing bolt for 1st and 2nd gearshift forks.

Remove gearshift fork (1) for reverse gear.

Press gearshift fork for 1st and 2nd gears against notch.
Pull out reverse gear.
Note when assembling: The chamfered side of the gears
must face towards the casing.

Press output drive shaft out of ball bearing or pull ball
bearing off output drive shaft.-Use Rillex 6306; long ver-
sion-.

Important: Note shim D.

Remove output drive shaft and gearshift fork for 1st and
2nd gears.

Important: The play between the follower and the sliding
sleeve must be 1.6 mm (0.0629") so as to avoid vibration of
the gearshift lever.
Follower A 9.5 mm (0.3740") inside sliding sleeve groove
B 11.1 mm (0.4370")
10.0 (0.3937") 11.6 mm
(0.4567")

Press off gears for 1st gear and reverse.

Push off needle bearing (1).
Lift off safety lock ring (2).
Remove synchronizing ring (3).
Important: Mark synchronizing ring for gear.

Press off synchromesh unit and 2nd gear.
Push off needle bearing.
Important: Mark synchronizing ring for gear.

Lift off circlip.
Press off synchromesh unit and 3rd gear.
Important: Mark synchronizing ring for gear.