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To assemble

To assemble

General measures before assembly


• Parts and housing should be thoroughly washed before assembly.

• Check the parts for wear. Change damaged or defective parts.

• If there was a lot of swarf in the gearbox, all bearings should be replaced. Always change both bearings on one shaft, even if only one is damaged.

• Change seals at the drive shafts.

• Oil all bearings and friction surfaces before assembly with the same type of oil used in the gearbox. See Technical Data Table of lubricants and sealing compounds .



1. Mount the clutch housing in the overhaul stand with 87 92 228 Holder, transmission .


2. Carefully scrape away any remains of old sealing compound from the mating surface without damaging the sealing surfaces. Make sure to clean away any remains of sealing compound from the gearcase.

3. Position the differential in the clutch housing and lubricate the bearing.

4. Mount the output shaft in its seat, lubricate the bear and insert the bearing race. Put on a bearing support and knock down. Use 87 92 202 Sleeve and 87 91 204 Sleeve, bearing race . Use 74 96 268 Thread locking adhesive on all bolts and fit them. Tighten the 3 bolts in the centre alternately.


Tightening torque: 45 Nm (33 lbf ft)

The outer bolts should only be tightened to:

Tightening torque 24 Nm (18 lbf ft)

5. Fit the gear wheels for 1st and 2nd gear with the synchromesh assembly on the output shaft with 87 92 103 Assembly fixture, 1 . Then fit the assembled parts on the output shaft. Fit the gear wheel for 3rd gear and spacer sleeve on the output shaft. Note that a used pinion must be turned the same way as before. Do not let the mounted wheels go too far down on the shaft, save 15 mm. Otherwise the input shaft cannot be fitted.


6. Place the input shaft in the housing and lubricate the bearing. Fit a cable tie to keep the gears on the input and output shafts meshed.

7. Press down the gears on the output shaft against the face of the clutch housing. Tap carefully with a hammer and 87 91 204 Sleeve, bearing and 87 90 867 Assembly ring, input shaft bearing until it is possible to fit a new collet and the 4th gear wheel. Turn the 4th gear wheel with its turned groove down.


8. Fit 87 91 261 Puller, pinion and pull down until the 4th gear pinion and wheel on the input and output shafts are at the same level. Cut off the cable ties and remove 87 92 103 Assembly fixture, 1 . Check that 1st and 2nd pinions run easily on the output shaft.


9. Lift the input shaft a little and fit the reverse gear wheel with pinion and synchromesh. The hole in the reverse shaft should be facing the channel in the clutch housing.


Important

If the oil hole is facing in the other direction, the reverse gear has been wrongly assembled. If this is the case, rectify the fault.


10. Fit the clutch housing shifting mechanism. The forks must be in neutral. Press the sleeve against the 2nd gear position on the output shaft. Press the sleeve into 4th gear position on the input shaft.


11. Place the 1st-2nd and 3rd-4th forks in the synchromesh sleeves and turn and push the mechanism into position. The synchromesh sleeves should be in the neutral position. Insert the locating sleeves and align the screws.

12. Fit the reverse lever with the two remaining bolts. Use 74 96 284 Thread locking adhesive on the short bolt. (The bolt hole opening into the clutch housing and thread locking adhesive is used to prevent oil leaks). Tighten the 3 bolts.


Tightening torque 24 Nm (18 lbf ft)

Important

The oil plate on the selector fork for reverse gear should be fitted under the edge of the gear mechanism.


13. Fit the fork to the reverse synchromesh sleeve. Check that the reverse gear selector fork enters the groove on the reverse fork. Then push in the shaft. Engage reverse gear using the selector mechanism and check that it is fully engaged.


14. Put the gear selector rod into position, sparingly lubricated with gearbox oil as described in Table of lubricants and sealing compound . Fit a new seal.


15. Insert and fit the driver in place. Slide in the gear selector rod and fit the bolt. Tighten the bolt to:

Tightening torque 24 Nm (18 lbf ft)

16. Check that all gears can be engaged. Also check the dual interlock feature by engaging 1st and then attempting to engage reverse by pushing in the reverse gear fork using a screwdriver. If reverse can be engaged, the locking pin in the selector mechanism must be checked.


17. Clean the sealing surfaces thoroughly, e.g. with 30 02 599 Cleaning agent . Apply 93 21 795 Flange sealant sparingly on the gearcase and clutch housing mating surfaces. Spread out the Loctite and allow to dry for a couple of minutes.


Important

Care must be taken when re-assembling the gearbox and applying flange sealant. If the sintered plug is replaced in the gearbox vent, oil in the gearbox can be expelled through the shaft seals.


18. Check that the reverse shaft is located correctly and that a new bolt can be fitted after fitting the gearcase. Place the gearcase on the clutch housing.


Important

Cover the holes so that nothing can enter the gearbox by mistake.


19. First secure the clutch housing and the gearcase loosely with two bolts. Then knock the guide sleeves upward. Fit the bolt for the reverse shaft loosely. If necessary, use a narrow screwdriver to align the bolt hole with the hole in the gearcasing. Fit the remaining bolts.


Tightening torque 24 Nm (18 lbf ft)

20. Tighten the screw for the reverse shaft. Note the O-ring!


Tightening torque 24 Nm (18 lbf ft)

21. Screw a new bolt to the reverse shaft support.

Tightening torque 20 Nm + 120° (15 lbf ft +120°)

22. Lay the bearing onto the output shaft, lubricate and pull it with 87 91 261 Puller, pinion . Pull only until it meets the collet.


23. Put the 5th gear onto the output shaft. Knock down the 5th gear wheel a short way with a hammer and 78 41 067 Sleeve, inner drive bearing . Fit 87 91 261 Puller, pinion . Pull down the gear against the bearing with the puller and fit a new nut.

Important

Lubricate the threads and faces of the nut with gearbox oil.


24. Fit 87 91 428 Driver onto the input shaft. Place the tip of the dial indicator on the input shaft bearing. Fit the drilling machine on the tool and "run" the gearbox to "settle" the bearings. First run and press for 20 revolutions and then zero the dial. Lift and run another 20 revolutions while reading the dial gauge (or until the reading has become stable). Measure the end float, which must be 0.09-0.15 mm. (The play will drop to 0.04-0.11 mm when the output shaft bearing has been adjusted to the correct pre-tension.) Adjust with shims under the bearing support as necessary. Shims are available in sizes 0.1, 0.15 and 0.30 mm.


Important

Tap carefully with a plastic hammer on the input shaft so that the bearing race by the 5th gear wheel is abut against the bearing support


• Thicker shim=more play

• Thinner shim=less play

• Shims are available in dimensions 0.10; 0.15; 0.30 mm

25. When adjusting axial play on input shaft:

Undo and remove the 4 screws from the bearing support. Refit the bearing support together with the correct package of shims and tighten alternately.

Tightening torque 38 Nm (28 lbf ft)

Check play again. Remove the three tools.

26. Fit 87 92 517 Holding tool, input shaft to support the input shaft while the 5th gear synchromesh hub is being knocked down.


27. Fit the 5th pinion with needle bearing. Lubricate the bearing.

28. Assemble the wire ring, the 3 leaf springs, the baulk ring and synchromesh hub with 87 92 582 Fixture, 5 . Knock down the hub with 78 41 067 Sleeve, inner driver bearing onto the input shaft splines.


The synchronisation stop lugs must be centred on the deep tooth gaps on the synchromesh hub .

29. Remove 87 92 582 Fixture, 5 .

30. Fit the 5th synchromesh sleeve with the tip angles down.

31. Remove 87 92 582 Fixture, 5

32. Fit 87 92 194 Dial gauge kit against the gear wheel with 87 90 727 Bracket, dial gauge. Engage 1st gear and press down the 5th gear sleeve so that the gearbox is "locked". Tighten the nut and check alternately with the dial gauge until an end play of 0.06 ±0.05 mm is attained on the output shaft. Use a short M8 bolt on the sealing face as a break point. Disengage 1st and 5th gear.


Important

Do not prise directly under the gear area, insert all the way.


33. Check and adjust the preload of the differential as follows:

Insert the bearing race, but not all the way in, and fit the bearing support without O-ring, shaft seal or shim. Tighten 4 bolts.

Tightening torque 24 Nm (18 lbf ft)


34. Fit 87 90 727 Bracket, dial gauge with 87 92 194 Dial gauge kit in the unoccupied hole. Adjust the tip against the differential housing. Run the output shaft with a drill machine and 87 92 053 Driver until the reading on the dial gauge has stabilised. Zero the dial gauge.


Warning

Watch your fingers when the gear wheel is moving.


35. Lift the differential with 87 91 337 Driver, measuring differential bearing torque , measuring differential bearing torque and read off the dial gauge. Correct shim dimension: measured value plus value from table.


Nominal value for differential preload

Old housing, 50,000 km

Old bearing, 50,000 km

0.20

Old housing, 50,000 km

New bearing

0.30

New housing

New bearing

0.35



• Thicker shims=increase preload

• Thinner shims=reduce preload

• Shims for the differential are available in sizes 0.10, 0.15, 0.30, 0.50 mm

36. Remove the dial gauge and stand plus the bearing support. Fit and lubricate the O-ring on the bearing support. Fit the bearing support with the calculated shim package. Screw down the bearing support until the "measured nominal value +0.15 mm" is left.


Important

The bearing support is tightened to torque after checking the bearing stress on the output shaft. A small axial play must be present in order not to disturb the measuring of the bearing stress on the output shaft.


37. Turn the gearbox so that it is in the same position as it would be in the car, i.e. horizontal.


38. Fit the M8 fuel hose (approx. 100 mm long) between 87 91 428 driver and hexagon socket (M8 with 1/2" drive). Check that no gear is engaged.

Important

The torque wrench is extremely sensitive to impact, overloading and rough treatment.


39. Connect the torque wrench (graduated in Nm) and rotate the wrench clockwise several revolutions at even speed. Read off the average value while rotating, normally 0.10-0.30 Nm.

If the value is greater than 0.30 Nm or if it varies greatly while rotating, either the baulk rings or dirt and cuttings in the bearing are slowing it down. Dismantle the gearbox and investigate the cause. Rotating the shaft backwards and forwards under axial load may help. The bearings must be oiled in later, however.

40. Turn the gearbox back around.

41. Place the tip of the dial gauge on the shaft as illustrated. Fit 87 92 053 Driver on the output shaft and "run" the gearbox with a drill machine to "settle" the bearings. Press and run for 20 revolutions first and then zero the dial gauge. Lift and run another 20 revolutions and read off the value (or run until the reading has stabilised). Remove the tool. Note the reading of the end play and then add on the nominal value . Remove the dial gauge.


Warning

Watch your fingers when the gear wheel is moving.


42. Engage 5th gear by pushing down the synchromesh sleeve. Engage 1st gear.

43. Remove 87 92 053 Driver from the output shaft.


44. Fit 87 92 061 Millimetre wheel, 27 mm onto the output shaft nut. Set the graduation of the tool (mm wheel) to the calculated value (measured + nominal, see example). Put a mark on one of the gear wheels with a felt tip or similar. Each small dash corresponds to 0.01 mm.


Nominal value, output shaft

mm

Old bearing, over 5,000 km

0.03

New bearing

0.15



Example: Measured value 0.43 + 0.03 (nominal value, over 5,000 km) =0.46 mm

Check the rolling torque on new bearings only

45. Pull in 2-3 stages until the tool's (mm wheel) zero graduation (0) is opposite the marked tooth. Measure the end play again as described in steps 41-45 to ensure the correct pre-tension is attained. Remove the tool and sleeve.

If the old bearing has been refitted on the output shaft, lock the nut and proceed to step 52.

If a new bearing has been fitted, do no lock the nut and continue with the next step.


46. Before taking a more precise measurement of the output shaft bearing preload, the following must be complied with:

Input shaft bearing (end play 0.09-0.15 mm)

Differential, bearing support fitted but not tightened (end play 0.10-0.20 mm)

All bearings oiled

47. Turn the gearbox so that it is in the same position as it would be in the car, i.e. horizontal. Disengage 1st gear and lift off the 5th synchromesh sleeve.

48. Place the torque wrench at the 5th gear nut output shaft. No gear must be engaged. Rotate the torque wrench several turns clockwise at an even speed. Read the average value from the display during rotation.


49. The reading should be 0.5-1.0 Nm.

Tighten the nut on the output shaft (5th and 1st engaged) two dashes on the millimetre graduation at a time on the 87 92 061 Millimetre wheel, 27 mm until the correct rolling torque (0.5-1.0 Nm) is attained.

Average torque varies greatly :

Cause:

Retarding baulk rings, swarf or dirt in the bearings.

Action:

Dismantle the gearbox.

Average torque higher than 1.0 Nm:

Cause:

Same as above or bearings too tight

Action:

Dismantle the gearbox and change clamping sleeve. The bearings should then be preloaded and checked.

50. Lock the nut

51. Turn the gearbox back around.

52. Lift off the 5th synchromesh sleeve and fit the 5th fork to the 5th synchromesh sleeve. Fit the fork and sleeve to the shaft.


Important

The sleeve may only be put on the synchromesh hub where the high lugs on the sleeve are, in front of the tooth gaps in the synchromesh hub that is in between the deep tooth gaps as shown in the illustration.


53. Tap the retention pin into the selector shaft.

54. Fit a new locking ring.

55. Tighten the screws for the differential bearing support.

Tightening torque 24 Nm (18 lbf ft)

56. Remove the cover from the hole in the gearcase and fit a new gasket and the end cover.


Tightening torque 24 Nm (18 lbf ft)

57. Refit the reversing light switch with a new gasket if it has been removed.

Tightening torque 24 Nm (18 lbf ft)

58. Check that the magnet is in position in the oil drain plug. Fit the plug.


Tightening torque 50 Nm (37 lbf ft)

59. Lubricate the seal rings for input shaft and drive shafts.


60. Oil is filled only after the drive shafts have been fitted to the gearbox and the gearbox has been fitted in the car. Oil capacity: 1.9 litres, see Technical Data Table of lubricants and sealing compounds .

61. Fit the slave cylinder, use 74 96 284 Thread locking adhesive on the bolts.

Tightening torque 10 Nm (7 lbf ft)

62. Fit delivery pipe in place and fit the bush.

63. Bleed the slave cylinder before fitting the gearbox. See Bleeding the slave cylinder .