(C) Assembly
When assembling oil all sliding parts and elements with
gearbox oil.
Fit on needle bearing and 3rd gear.
Place synchronizing ring and synchromesh unit on the
thicker side of the hub and press on.
Attach circlip without play.

Fit on needle bearing and 2nd gear.
Place synchronizing ring in pre-assembled synchromesh
unit.
Press on synchromesh unit and compensate axially (without
play) by means of retaining ring.

Place synchronizing ring in synchromesh unit.
Fit on needle bearing and 1st gear.
Press on reverse gear with thicker hub facing to the outside.

Measure distance A from synchromesh unit hub to polished
surface of reverse gear hub.

Insert locking ring in new C 3 bearing.
Press in ball bearing to its fullest extent.

Measure distance B from housing joint face - without
gasket - to ball bearing inner race.
To determine thickness of shim D.
Example:

A	151.0 mm (5.944")
B	C actual
54.3 mm (2.137")	C theoretical
53.5 mm (2.106")	Shim D
0.8 mm (0.031")

Shim D is available in the following thickness:
0.6, 0.8, 1.0, 1.2 and 1.4 mm
(0.023", 0.031", 0.039", 0.047" and 0.055").

Remove ball bearing.
Fit ball bearing with shim D thickness as calculated.

Use grease when refitting stop pin and pressure springs.

Position selector fork 1st and 2nd gears in shift sleeve.
Press drive shaft into ball bearing in housing.

Engage 2nd gear.
Press selector fork against stop.
Position reverse gear pinion with relieved tooth face side
towards housing approximately 1 cm (0.394") on to reverse
gear shaft.
Insert selector fork for reverse gear and secure.
Fit bearing pin for selector fork 1st and 2nd gears.
Press 2nd gear into neutral position.

Fit synchromesh springs with spring ends offset.
Engage pressure pieces.
Press sliding sleeves onto synchromesh.

Position roller rim on drive shaft.
Insert synchromesh ring.
Fit driving shaft.

Insert layshaft as support.

Heat ball bearing inner race to approx.
90° C (194° F), push on to layshaft and press into housing.
Allow ball bearing to project
(dimension D = approx. 5 mm / 0.196").

Measure distance A with gasket in position.

Measure dimension B.

Calculate thickness of shim C as follows:
Example: A = 3.0 (0.118")
B = 3.6 (0.141")
------------------------
C = 0.6 (0.023")
Shimming accuracy ± 0.06 (0.002").
Fit waher (1) and speedometer pinion.
Stick shim C on to speedometer cover with grease.

Fit cover and drive flange.
Note! Flat nuts (1 and 2) below vibration damper.

Secure selector fork 3rd and 4th gears.
First of all insert bearing pin on left in direction of travel.
Fit all shift rails.
Fit front of housing, vibration damper and shift arm.
Measure distance A from housing joint face to contact
face of ball bearing.

Determine dimension B from ball bearing edge to lock ring.

C less 0.5-0.8 mm (0.019-0.031") will give the thickness of
shim D.
Example: A = 15,7 mm (0.618")
B = 13.8 mm (0.543")
----------------------------------
C = 1.9 mm (0.074")"
- 0.5 mm (0.019")
--------------------------------
D = 1,4 mm (0.055")
---------------------------------
Fit shim D on driving shaft.
Press ball bearing on to driving shaft with pressing on
tool 611 and into housing.
Lock pressing on tool 611 with bolt and screwdriver.

Shim clearance between ball bearing inner race and
circlip to zero.

Place gasket in position.
Measure distance A between gasket and ball bearing top
face.

B (0.1-0.2 mm / 0.004-0.008") recommended end float of
layshaft subtracted from A will give the thickness of
shims C.
Example: A = 1.3 mm (0.051")
- B = 0.1 mm (0.004")
----------------------------------
C = 1.2 mm (0.047")
---------------------------------
Measure distance D between joint face and turn face of
guide sleeve.

Measure distance E from ball bearing top face to gasket.

To determine thickness of shim, accuracy ± 0.05 mm (0.002").
Example: D = 5.8 mm (0.228")
E = 4,7 mm (0.185")
--------------------------------
F = 1.1 mm (0.043")
Secure shim F in guide flange with grease.
Place shim C on ball bearing.
Secure guide flange.