Gear Carrier Assembly/Adjustment 4 Speed

Gear Carrier/Gearshift Housing Assembly





- Press main shaft with shift rod into gear carrier





- Install pinion shaft with shift rod
- Shift into 3rd gear
- Shift into neutral
- Install pinion shaft needle bearing





- Install circlip
- Make sure lugs at circlip are below teeth of pinion head (arrow)





- Install shim S3
- Install new gasket
- Align shift rod
- Align flat on piston with recess in housing
- Tap on pinion with plastic hammer to install
- Make sure teeth of gears match properly
- Install retaining ring and tighten to 225 Nm (162 ft lb) then loosen and retighten to 225 Nm (162 ft lb)





- Peen retaining ring twice with suitable tool A (local manufacture)
- Attach gear carrier to transmission housing and tighten bolts to 20 Nm (14 ft lb)





Determining Thickness Of Spacer For Reverse Gear
- Install circlip
- Measure distance C
- Calculate spacer needed
Example: Measurement c (29.1 mm)
Subtract measurement d (24.7 mm)
Equals thickness of spacer (4.4 mm)





- Install spacer (selected from chart), reverse gear, needle bearing and circlip





- Install synchronizer
- Install circlip
- Install reverse gear
- Groove in gear must face cover
- Install needle bearing and washers
- Install shift rod/fork bolt and tighten to 20 Nm (14 ft lb)
- Before installing, coat thread of bolt with D6-locking compound
- Install new gasket
- Install cover
- Align shaft and bore in cover
- Tighten bolts to 20 Nm (14 ft lb)
- Install shift shaft
- Slotted side toward differential housing
- Install new gasket
- Install spring
- Install cover and tighten bolts to 15 Nm (10 ft lb)
- Install back-up light switch
- Install shift shaft lever