Removal and assembly notes Removal

1. Remove end cap, piercing center of rubber with a large screwdriver. Push in screwdriver laterally between cap and oil catcher and twist screwdriver to lever off the cap.

2. To undo the bolt (No. 3), the drive shaft must be locked. To do so, remove the shift cylinder and engage two gears.

3. Pull out four-point bearing inner race with thrust piece 9535, internal puller 30...37 mm (e.g. Kukko 21/5) and support. Make sure the internal puller engages into the circumferential groove in the inner race.

4. Pull off four-point bearing inner race using thrust piece 9536 and two-way puller.

5. Push out spiral pin for driver, using Special Tool 3276.


The spiral pin must not be driven out as this will damage the mountings of the shift rod.


A = Spiral pin

6. Pull off bearing inner race and synchronizer hub with thrust piece 9536 and two-way puller.



The 6th gear fixed gearwheel can only be replaced if the end shield has been removed (refer to page 34 - 21).


1. Check synchronizing ring for wear, pressing the synchronizing ring into the sliding sleeve and measuring gap „a" in three places (A, B and C) using a feeler gauge. Add the measured values and divide by 3. The result must not be less than 0.5 mm.

2. Heat synchronizer hub to approx. 100°C and press in to stop, observing correct position. Installation position: The protruding front area (arrow 1) points towards the gearwheel for 5th gear and the oil groove (arrow 3) must line up with the oil bore (arrow 2).

3. Install sliding sleeve for 5th and 6th gear complete with shift fork and driver, observing correct position. Installation position: Marks on synchromesh hub and sliding sleeve must line up.

4. Press in roll pin, using Special Tool 3276.


5. Install oil catcher in correct position. Installation position: Large oil bore must line up with the groove in the cover.


A = Large oil bore B = Groove in cover

Do It Yourself Car Diagnosis

Do It Yourself Car Diagnosis

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