26
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 While holding the hub (3) down, lift the
outer synchronizer ring (4) and engage
with the hub itself, taking care not to let
the balls fall out of their seats – Fig. 9.

Fig. 9

3

4
 Once the outer ring is engaged correctly
with the hub, retrieve the cable tie loop
(7), which will have slipped off during the
operation – Fig. 10.

Fig. 10

7

 Fit the indicated blocks in the relative seats
on the complete assembled synchronizer
(8), pressing gently by hand to fasten into
place – Fig. 11.

8

Fig. 11

27
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 Once the assembly procedure is finished,
the complete assembled synchronizer (8)
should look like the example shown in the
photo aside – Fig. 12.

8

Fig. 12

Fitting the new gearbox speed sensor

3rd

7th

5th

1st

Primary
7th speed

Fig. 1

The gears removed in the procedure to replace the speed sensor are illustrated in the image
above. The diameters of the gears are indicated as follows to facilitate identification of the
gears themselves and reassembly – Fig. 1.
 3rd speed _ Ø 121.60 mm
 5th speed _ Ø 90.30 mm
 7th speed _ Ø 73.40 mm
 1st speed _ Ø 150 mm
 Primary 7th speed _ Ø 107.37 mm
28
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 Using a Teflon spatula, remove all traces of
sealant from the surfaces on the interface
plate and the gear housing – Fig. 2.
Note: Be careful to not damage the surfaces
of the two housings.

Fig. 2

 Using a Teflon spatula, remove all traces of
sealant from the holes on the interface plate
and the differential housing – Fig. 3.
Note: Be careful to not damage the surfaces
of the two housings.

Fig. 3

 Using a lint-free cloth and heptane, remove
all traces of adhesive and/or dirt from the
surfaces and holes of the interface plate and
from the gear housing – Fig. 4.

Fig. 4
29
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 Aspirate all residue of adhesive and/or dirt
from the surfaces of the interface plate and
from the gear housing – Fig. 5.
Note: DO NOT blow or use cloth to remove
dirt and/or dust.

Fig. 5
Fig. 6

 Clean the speed sensor fixing screws seats on
the gear housing to remove all residue of
Loctite – Fig. 6.
 Fit the pins of the new speed sensor in the
relative seats indicated on the gear housing –
Fig. 6.

 Apply Loctite 243 to the threads of the three
new screws indicated, then tighten the screws
to a torque of 6 Nm to fasten the speed sensor
(1) – Fig. 7.

Fig. 7

52
1

 Connect the Park Lock connector (52) – Fig.
7.

30
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Feed the connector (2) of the speed sensor
through the respective hole in the housing, then
fit into the adapter (3), after replacing the
relative O-ring – Fig. 8.

Fig. 8

2

3

 Fit the new fastener clip (3) on the connector
(2) of the speed sensor – Fig. 9.

3

 Fit the adapter in the relative hole on the
housing, then fit the new seeger ring (4) in the
relative seat - Fig. 9.

2

Fig. 9

4

Fig. 10

 Make a loop in the gearbox speed sensor
wiring and fasten in this position, together
with the two Park Lock cables, by fitting a high
temperature cable tie in the point indicated in
the photo aside – Fig. 10.
Note: Ensure that none of the wiring is in
contact with the gearbox casting.

31
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 Install the new O-ring (5) on the interface plate
– Fig. 11.

5

Fig. 11

 Lubricate the interior of the Corteco ring on the
speed sensor side of the gear housing with
SEGO grease – Fig. 12.

Fig. 12

 Lubricate the seat of the even gear primary shaft
with SEGO grease – Fig. 13.

Fig. 13

32
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Ensure that the recess in the shim (53) is
aligned with the pin on the reverse shaft (54)
indicated – Fig. 14.

Fig. 14

54

 Ensure that the reverse shaft (54) in seated
correctly – Fig. 14.
53

Fig. 15

Place the height checking template AV 8824
on the end of the reverse shaft (54), and
ensure that it is also in contact with the shim
in the position indicated – Fig. 15.If not, check
if the reverse shaft (54) has dropped fully into
its seat – Fig. 15.

AV 8824

54

Ensure that the hole indicated on the reverse
shaft (54) is turned towards the indicated hole
on the support tool – Fig. 16.

54

Fig. 16
33
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Ensure that the hole indicated on the Park Lock
pin is turned towards the relative hole on the
gear housing – Fig. 17.

Fig. 17

 Clean the indicated hole to remove all residue
of Loctite – Fig. 17.

 Apply a continuous bead of Loctite 5970 to
the outer mating surface of the gear housing,
on the interface plate side – Fig. 18.

Fig. 18

 Apply a continuous bead of Loctite 5970
around the holes in the outer mating surface
of the gear housing, on the interface plate
side, as shown in the photo aside – Fig. 19.

Fig. 19

34
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 The continuous bead of Loctite 5970 must be
applied like the example shown in the photo
aside – Fig. 20.

Fig. 20

Fig. 21

AV 8607

 Fit the two alignment pins 95978607 (AV
8607) in the gear housing, in the positions
indicated in the photo alongside – Fig. 21.

AV 8607
Fig. 22

 Fit the gear housing (6) onto the interface
plate, aligning the pins, rods and shafts
correctly – Fig. 22.

6

35
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 Fit the gear housing (6), with the rods
protruding from the housing itself as shown
in the detail in the photo aside – Fig. 23.

Fig. 23

6
 Fit the cones AV 8820 on the two rods – Fig.
24.

Fig. 24

AV 8820

 While pressing down on the two cones AV
8820 by hand, lower the gear housing (6) fully
into its seat, so that the pins engage in the
grooves on the rods – Fig. 25.

6

AV 8820

AV 8820

Fig. 25

AV 8820
36

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 After checking that the indicated pins are
engaged correctly in the grooves on the
respective rods (7), remove the cones AV 8820
– Fig. 26.

AV 8820

7
Fig. 26

 Check that the seat ring of the primary shaft (8)
is installed correctly in the respective corteco
ring indicated – Fig. 27.

Fig. 27

8

 Remove the pins installed previously and handtighten four suitable screws in the positions
indicated – Fig. 28.

Fig. 28
37
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 A) Hand-tighten the new screws as indicated –
Fig. 29.

Fig. 29

 B) Hand-tighten the new screws as indicated –
Fig. 30.

Fig. 30

 Tighten the new screws fitted in steps A and B
to a torque of 34 Nm in a cross pattern.

Fig. 31

 Apply an even layer of Loctite 5970 under the
head of the new reverse gear screw – Fig. 31.

38
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 Apply Loctite 243 to the thread of the reverse
gear screw Fig. 32.

Fig. 32

Fig. 33

 Hand-tighten the fastener screw of the Reverse
shaft, then torque the screw to 24 Nm class A–
Fig. 33.

Fig. 34

 Apply an even layer of Loctite 5970 under the
head of the new Park Lock pin screw – Fig. 34.
 Apply Loctite 243 to the thread of the Park Lock
pin screw – Fig. 34.

39
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 Tighten the screw fastening the Park Lock pin to
a torque of 24 Nm class A – Fig. 35.

Fig. 44Fig. 35

Fig. 36

 Lubricate the inner surface of the corteco ring
(10) serving as the seat for the odd gear primary
shaft with SEGO grease – Fig. 36.

10

Fig. 37

 Turn the gearbox into a horizontal position –
Fig. 37.
 Fit the roller bearing cage (11) onto the R-4th3rd-1st gear secondary shaft – Fig. 37.

11

40
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