2585316 - 2110B42 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 any gear using the gear selector/engagement lever.1. Undo the bolt securing the 5th speed selector fork to the main shaft.Engage 5th speed, pressing the selector fork onto the main shaft.

The simultaneous enagement of two gears will result in the gearbox shafts locking.

2. Remove the staking and loosen the ring nuts for the main and layshafts.Position the 5th speed selector fork in neutral.

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

1. Completely undo the ring nuts for the main and layshafts.2. Remove the 5th speed driven gear.3. Remove the 5th speed synchronizer rollers and springs retaining flange.4. Remove the 5th speed selector fork.5. Remove the 5th speed sliding sleeve.6. Remove the 5th speed hub pre-synchronizer mountings.7. Remove the 5th speed sliding sleeve hub.8. Remove the 5th speed synchronizer ring.9. Remove the 5th speed drive gear.10. Remove the needle bearing for the 5th speed drive gear.11. Remove the 5th speed drive gear bush. 1. Dismantle the 5th speed engagement fork, lock the sleeve (1a) in the vice, with the protective plates fitted then, use a brass drift (1b), alternately on the two ends of the selector fork (1c) until it is released from the sleeve.

take care not to damage the tapered part of the sleeve and the ends of the selector fork with the drift.

Refitting ( Removing ) 1. Fit the 5th speed drive gear bush.2. Fit the needle bearing for the 5th speed drive gear.3. Fit the 5th speed drive gear.4. Fit the 5th speed synchronizer gear.5. Fit the 5th speed sliding sleeve hub.6. Fit the 5th speed sliding sleeve.7. Fit the pre-synchronizer mountings in the 5th speed sliding sleeve hub.8. Fit the 5th speed control fork.9. Fit the 5th speed synchronizer ring and roller retaining flange.10. Fit the 5th speed driven gear.11. Tighten the new rings nuts for the main and layshafts to torque.

	Fastening	Component	Ø	Value(daNm)
11	Ring nut	GEAR SHAFTS	M20	11.8

1. Tighten the 5th speed selector fork bolt to torque.

	Fastening	Component	Ø	Value(daNm)
12	Bolt	GEARBOX INTERNAL CONTROLS	M6	1.8

1. Reassemble the 5th speed engagement fork, locking the sleeve in the vice with the protective plates fitted;2. Position the selector fork that the its tapered part is in the same direction as that of the sleeve, resting it against the side of the sleeve which has the smaller diameter;fit the selector fork manually, exerting the necessary pressure, until it is completely inserted in the sleeve.

When the fitting is complete, check that the sleeve can rotate freely inside the selector fork.

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	2.5