 Fit the elastic band (16) to keep the
interlock raised – Fig. 29.

16

13
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Fig. 30

 With the gearbox still in a horizontal position,
simultaneously remove the odd gear primary
shaft (17), the 5th-7th gear synchronizer (18)
and the 5th speed gear (19) – Fig. 30.
 Remove the elastic band fitted previously.

19
17
18

 Remove the roller bearing cage (20) – Fig. 31.

Fig. 31

20

 Fit the bushing AV 8628 on the R-4th-3rd-1st
speed secondary shaft – Fig. 32.

Fig. 32

AV 8628
14
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 Fit the bushing AV 8628 on the synchronizer
hub (21), aligning the indicated holes – Fig.
33.

Fig. 33

21

AV 8628

 Fit the three pins in the holes spaced at 120°
intervals on the bushing AV 8628 – Fig. 34.

Fig. 34

AV 8628

 Ensure that the pins are inserted fully in the
holes, as shown in the photo aside – Fig. 35.

Fig. 35

15
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 Fit the clamp (22) around the
circumference of the bushing AV 8628,
over the pins fitted previously – Fig. 36.

Fig. 36

22

AV 8628

 Fit the cap AV 8613 on the R-4th-3rd-1st
secondary shaft, then fit the extractor tool
USAG 454N/3 on the tool AV 8628 – Fig.
37.

AV 8628
AV 8613

 Detach and remove the bushing (12)
from the R-4th-3rd-1st gear secondary
shaft – Fig. 37.

12

Fig. 37

 Place the assembly on the bench.

12

 Remove the bushing (12) from the tool
AV 8628 – Fig. 38.

Fig. 38

AV 8628

16
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Loosen then remove the clamp (23) from the
bushing AV 8628 – Fig. 39.

Fig. 39

23

AV 8628

 Use a magnet to remove the three pins
indicated from the bushing AV 8628 – Fig.
40.

21

 Retrieve the synchronizer hub (21) – Fig. 40.

AV 8628

 Remove the synchronizer rings (24) – Fig.
41.

Fig. 40

24

Fig. 41
17
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 Remove the 3rd speed gear (25) – Fig. 42.

Fig. 42

25

Fig. 43

 Remove the roller bearing cage (26) – Fig. 43.
26

 Fit the rod AV 8823 into the hole in the
indicated pin of the Park Lock – Fig. 44.

Fig. 44

 Applying leverage to the rod, pull the indicated
pin of the Park Lock out as far as possible in
order to fit the cylinder AV 8823 from above,
as shown in the photo – Fig. 44.
 Release the rod gradually, so that it rests
against the pin fitted in the previous step – Fig.
44.

AV 8823

18
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 Undo the Park Lock pin fastener screw – Fig. 45.

Fig. 45

Fig. 46

 Loosen the fastener screw of the R shaft –
Fig. 46.

 Fit the additional lower bracket (27) on tool
AM 107314, fastening with the respective
fastener screws indicated – Fig. 47.

27

Fig. 47

AM 107314
19
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 Fit the additional left hand lateral bracket (28)
on tool AM 107314, fastening with the
respective fastener screws and nuts indicated –
Fig. 48.

AM 107314

28

Fig. 48

 Remove the left hand mount (29) of tool AM
107314, undoing the relative fastener screws –
Fig. 49.

AM 107314

29

Fig. 49

 Remove the right hand mount (30) of tool AM
107314, undoing the relative fastener screws –
Fig. 50.

Fig. 50

AM 107314

30

20
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On the left hand side of the gearbox, undo the
indicated screws fastening the gear housing –
Fig. 51.

Fig. 51

 On the front side of the gearbox, undo the
indicated screws fastening the gear housing
– Fig. 52.

Fig. 52

 Remove the seeger ring (31), then remove
the Park Lock pin (32) – Fig. 53.

31
32
Fig. 53
21
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 On the right hand side of the gearbox,
apply a lever (33) in the position indicated
to detach the gear housing (34) – Fig. 54.

34
33

Fig. 54

 On the left hand side of the gearbox, apply
a lever (33) in the position indicated to
detach the gear housing (34) – Fig. 55.

 Detach the gear housing (34) from the
plate, retrieving the small O-ring from the
interface plate – Fig. 56.

33

34

Fig. 55

Fig. 56

34
22
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 With the gear housing on the bench, replace
the speed sensor as follows.
 Remove the seeger ring (35) – Fig. 57.
 Pull the speed sensor connector (36) as far as
possible out of the gear housing – Fig. 57.

36

35

Fig. 57

 Detach the retainer clip (37) from the speed
sensor connector – Fig. 58.

37

 Remove the adapter (39) from the speed
sensor (38) – Fig. 59.

Fig. 58
Fig. 59

38

39
23
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 Disconnect the Park Lock connector (41)
– Fig. 60.

41

 Loosen the indicated screws, then remove
the speed sensor (40), pulling the relative
connector out of the gear housing, and
replace – Fig. 60.

Fig. 60

40

Reassembling synchronizers
 Place the gear (1) (the 5th speed gear is
shown in this example) on a work surface,
with the side shown in the figure aside
facing upwards – Fig. 1.
Note: The gear (1) is only used as a base
to facilitate reassembly of the
synchronizer.

 Fit the R-4th-3rd-1st speed secondary
shaft end shim (2) on the gear, as shown
in the photo aside – Fig. 2.

Fig. 1

1

2

Fig. 2

Note: The shim ring (2) is only used as a
base to facilitate reassembly of the
synchronizer.

24
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 Fit the synchronizer hub (3) – Fig. 3.

Fig. 3

3

4

 Fit the outer ring (4) of the synchronizer on
the relative hub (3) – Fig. 4.

6

 Align the tooth with a single central notch
(5) on the ring with the recess on the hub
(3) (indicated by blue line), then align the
tooth with two recesses (6) with the
machined groove on the hub (3) (indicated
by green line) – Fig. 4.

5

3

Fig. 4

 Push the outer synchronizer ring (4) down
completely to allow access to the holes on
the outer circumference of the hub – Fig. 5.
 Fit the three springs indicated into the
holes in the outer circumference of the hub
(3), which are also aligned with the
machined grooves in the hub itself
indicated by green lines (3) – Fig. 5.

3

4

Fig. 5
25

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 Fit the three balls on the outer
synchronizer ring (4), over the three
springs installed previously – Fig. 6.

Fig. 6

4
 Join the opposite ends of two cable ties
together to form a loop – Fig. 7.

Fig. 7

 Fit the loop (7) around the
synchronizer hub, over the three balls
fitted previously – Fig. 7.

7
Fig. 8

 Working carefully, tighten the loop (7)
around the synchronizer hub, pushing
the balls into the respective holes – Fig.
8.
Note: Ensure that the balls remain
secured correctly in their seats.

7