Gearbox Assembly

Remove the outer race of the front tapered roller bearing of the output shaft, having previously removed the cylindrical pin on gearbox type 013, and on gearbox type 093 by unscrewing the hexagon socket head bolt. If necessary, press in a new ring.

Install the locks and locks of the shift fork rods in the correct position.

Install the output shaft with the shift fork of I and II gears into the gearbox housing.

Install the reverse intermediate gear on the axle, then press the axle in.

Install the input shaft with the shift fork of III and IV gears into the crankcase.

Set the 1st and 2nd gear shift forks, as well as the 5th gear and reverse shift forks, to the neutral position.

Install the 3rd and 4th gear fork shaft together with the latch pre-lubricated with grease, insert the spring cotter pin into the fork, holding the shaft with a hammer.

Press on the first inner race of the output shaft rear double row tapered roller bearing.

Install the support washer on the input shaft with the protruding part towards the gearbox housing. Heat up to a temperature of about 120°C and install the inner race of the V gear bearing in place until it stops, using drift 30-23 if necessary. While doing this, hold the input shaft.

Heat up to a temperature of about 120°C and install on the output shaft, pushing it to the stop, the gear of the V gear, using, if necessary, a mandrel 30-100. While doing this, hold the output shaft.

Put the 5th gear on the input shaft together with the hub and the synchronizer sleeve, the needle bearing and the 5th gear fork. Fasten the fork to the stem with a spring cotter pin, while holding the stem with a hammer.


Install the 5th gear synchronizer ring.

Heat up to a temperature of about 120°C and install the 5th gear synchronizer assembly in place. If necessary, use drift 30-23 to push it up to the stop on the input shaft. In doing so, block the input shaft.

Install a new gasket and attach the gearbox housing with input and output shafts installed to the clutch housing. Put the mounting studs in place and tighten the crankcase mounting bolts to a torque of 2.5 kgf·m.

Engage a gear and lock the input shaft with lock 29441.

Tighten the nut at the rear end of the output shaft to 10.0 kgfm and lock it.

Push forward the leash of the fork rod of 1st and 2nd gears and engage the 3rd gear by pulling back the fork rod.

Install the gear selector:

• put the ends of the spring on the stem of the shift fork of III and IV gears;
• slide the lever of the gear selector rod onto the fork rod of III and IV gears;
• align the selector rod and insert it into the guide bush.

Set fork rods to neutral position.

Align the holes of the leash and the stem of the 1st and 2nd gear forks and insert the spring cotter pin.

Install a new gasket and replace the rear cover of the gearbox housing using an M10 threaded rod.

Tighten the hex bolt at the rear end of the input shaft to 4.5 kgf·m.

Tighten the crankcase rear cover mounting bolts to a torque of 2.5 kg.m, having previously applied a special VW D3 type glue to their threads.

Install a new plug in the rear cover of the gearbox housing.