125001239 - 2010B42 5TH SPEED GEARS OF MANUAL GEARBOX WITH DIFFERENTIAL - R+R WITH GEARBOX REMOVED

Removing ( Refitting ) 1. Undo the bolts (1a) and remove the rear cover (1b). Engage 5^thspeed pressing the selector fork on the main shaft.Engage any gear using the gear selector/engagement lever.

The simultaneous engagement of two gears will cause the gearbox shafts to lock.

1. Undo the 5^thspeed selector fork bolt.2. Remove the staking and loosen the ring nuts for the main and layshafts.Place the selector fork for 5^thspeed in neutral.

Positioning the selector fork for 5 th speed in neutral is necessary to prevent the synchronizer rollers from being lost.

1. Completely undo the ring nuts for the main and layshafts.2. Remove the 5^thspeed driven gear.3. Remove the roller and spring retaining flange for the 5^thspeed synchronizer.4. Remove the 5^thspeed selector fork.5. Remove the 5^thspeed sliding sleeve.6. Remove the springs (6a) and rollers (6b) for the 5^thspeed hub.7. Remove the hub for the 5^thspeed sliding sleeve.8. Remove the 5^thspeed synchronizer ring.9. Remove the 5^thspeed drive gear.10. Remove the needle bearing for the 5^thspeed drive gear.11. Remove the bush for the 5^thspeed drive gear. Refitting ( Removing ) Fit the 5^thspeed drive gear bush.Fit the needle bearing for the 5^thspeed drive gear.Fit the 5^thspeed drive gear.Fit the 5^thspeed synchronizer gear.Fit the 5^thspeed sliding sleeve hub.Fit the 5^thspeed sliding sleeve.Fit the srpings and rollers in the 5^thspeed slding sleeve hub.

To avoid losing the synchronizer springs and rollers, place the sliding sleeve in neutral.

Fit the 5^thspeed selector fork.Fit the 5^thspeed synchronizer springs and rollers retaining flange.Fit the 5^thspeed driven gear.Tighten the new ring nuts for the main and layshafts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Ring nut	GEAR SHAFTS	M20	10 - 12.4

Tighten the bolt for the 5^thspeed selector fork to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	5thª speed selector fork	M6	1.5 - 1.9

Apply sealant to the contact surfaces between the main and layshaft rear bearing retaining plate and the rear cover.

	Type	Component	Name	Qty.
-	Sealant	GEARBOX SEALS/GASKETS	Loctite 573	-

Fit the rear cover and fix it tightening the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX REAR COVER	M8	2.1 - 2.6