For 1990-2009 cars

#### Special Tools

• | KM-113-2 Bracket

• | KM-308 Remover/Installer

• | KM-446 Installer Drift

• | KM-447 Remover/Installer

• | KM-454-B Remover/Installer

• | KM-473 Sleeve

• | KM-523 Remover/Installer

• | KM-552 Fixture

• | KM-982 Mount

• | KM-6037 Adapter

• | KM-6115 Bracket for Clutch Housing

• | KM-6155 Guide Pins

• | KM-6157 Assembly Sleeve

• | KM-6336 Installer

• | KM-6337 Installer

• | KM-6338 Installer

• | KM-6339 Installer

• | MKM-536-A Friction Coefficient Meter

1. Attach new transmission housing to KM-6115 .
2. Fit roller bearing (3) for main shaft.

Install roller bearing flush in transmission housing with KM-454-B -3 (5) and KM-454-B -4 (4).

Important: Needle bearing side with writing points to transmission.

3. Fit needle bearing (2) for drive shaft.

Install needle bearing flush in transmission housing with KM-454-B -2 (6) and KM-454-B -4 (1).

4. Insert differential into transmission from below.

Important: Align bearing race with marking previously made.

5. Install bearing race with KM-447 (2).

Important: The connection must be oil-tight.

6. Coat thread (arrow) and new O-ring (1) with multi-purpose grease.
7. Check clearance between tapered roller bearing and differential housing (external LU).

Important: Adjust bearing pre-tension by screwing in bearing race.

8. Check breakaway torque with MKM-536-A (1) and KM-6037 (2).

Important: Adhere to specified breakaway torques.

9. Test rpm 1 revolution per second.

• | Re-use all the dismantled parts. Adjust to marking.

• | Re-use bearing, replacement of bearing race, bearing flange, differential or transmission housing.

Breakaway Torque
60...100 Ncm

• | Bearing as new part

Breakaway Torque
150...210 Ncm

10. Clean thread for retaining plate bolt in transmission housing.

Notice: Refer to Fastener Notice in the Preface section.

Important: Insert bolt with locking compound.

11. Attach retaining plate for bearing ring.
12. Re-cut thread.

Tighten
Tighten bolt 9 N·m (80 lb in).

Important: Note seating and condition of the O-ring (2). Damage to or absence of the O-ring leads to leaks.

13. Install fastening sleeve for pressure line (1). The lug (arrow) on the sleeve must sit in the groove in the clutch housing.
14. Engage pressure line in fastening sleeve.
15. Clean 3x thread (1) in transmission.
16. Install central release (1).

• | Attach assembly aid MTA KM-6157 (3) to drive shaft (2), so that the seal ring (arrow) is not damaged

• | Lightly coat seal ring in central release with transmission fluid.

• | Preassemble 3x bolt evenly in contact with the flange. Use new bolts.

| Important: It is essential to avoid pulling the central release at an angle.

• | Tighten 3x bolt

Tighten
Tighten bolt to 5 N·m (44 lb in)

17. Attach pressure line (1).

Tighten
Tighten retaining nut 14 N·m (10 lb ft).

18. Lubricate rotating parts on their bearing, running, seating, and pressure surfaces using transmission fluid.
19. Install bearing for main and drive shafts.

• | Press in 2x bearings using KM-523 -1 (1) and KM-6336 (2)

• | Fit 2x retaining rings (3) -- check retaining ring for proper seating.

Important: Check shaft for proper seating.

20. Fit main and drive shafts.

• | Place main shaft (1) and drive shaft (4) on KM-6337 (5)

• | Place end shield (3) on main shaft and drive shaft and press on with KM-6338 (2)

21. Fit 5th gear bearing sleeve (1).

• | Locate end shield on KM-6337 (3)

• | Press bearing sleeve on main shaft using KM-6339 (2)

Important: Note installation position.

22. Fit reverse gear axle (1).

• | Locate reverse idler on axle -- note installation position, shift fork groove to top

• | Press reverse gear axle with inserted lock ball (arrow) to stop in end shield

23. Attach end shield to KM-552 (2) .
24. Attach end shield to KM-113-2 (1) using KM-552 (2) .
25. Fit locking pin (5). Insert 3rd/4th gear and reverse gear locking pins.

Important: To relieve pressure on gearshift rod guides in end shield, support gearshift rods with wooden wedge (1) when securing with pin.

26. Fit reverse gear shift fork.

• | Insert reverse gear shift fork (6) and gearshift rod

• | Insert new roll pin using KM-308 (arrow) -- allow new roll pin to protrude approximately 2 mm (0.08 in)

Important: To relieve pressure on gearshift rod guides in end shield, support gearshift rods with wooden wedge (2) when securing with pin.

27. Fit 1st/2nd gear shift fork.

• | Insert 1st/2nd gear shift fork (4) and gearshift rod (1)

• | Insert new roll pin using KM-308 (3) -- allow new roll pin to protrude approximately 2 mm (0.08 in)

28. Insert 5th gear (4) shift driver.

Important: To relieve pressure on gearshift rod guides in end shield, support gearshift rods with wooden wedge when securing with pin.

29. Fit 3rd/4th gear shift fork.

• | Insert 3rd/4th gear shift fork (2) and gearshift rod (1)

• | Insert new roll pin using KM-308 (3) -- allow roll pin to protrude approximately 2 mm (0.08 in)

30. Fit locking plugs.

Install 4x locking plugs (5-7) -- drive to stop with plastic hammer or soft metal drift.

31. Bring gear shift fork into neutral speed position.
32. Engage gear 3x.

• | Engage 2nd gear

• | Engage 3rd gear

• | Engage 5th gear

33. Attach bridge (2) for locking bolt on end shield.

Important: Coat bolts with locking compound

34. Screw in 2x new bolt.
35. Move gearshift fork 1st/2nd gear into neutral.
36. Fasten 2x bolt for bridge.

Tighten
Tighten 2x bolt for bridge 7 N·m (62 lb ft)

37. Bring shift fork into neutral position.
38. Attach bearing support (4) to end shield with pawl (3).

Important: Coat bolts with locking compound.

39. Tighten 2x bolt.

Tighten
Tighten 2x bolt 9 N·m (80 lb ft).

Important: Note installation direction. Long gear hub points to end shield.

40. Install 5th gear (driven) (2).

• | Insert end shield with main and drive shafts in KM-6337 (3)

• | Press on 5th gear using KM-473 (1)

| Important: Retaining ring must engage completely.

• | fit new retaining ring

41. Fit 5th gear (5) (driven).

| Important: Ensure correct seating of slotted needle bearings.

• | Coat needle bearings (6) with transmission fluid and place on main shaft

• | Locate 5th gear and 5th gear synchronizer ring on main shaft

42. Press on 5th gear synchro body assembly.

• | Insert end shield in KM-6337

| Important: Synchronizer ring lugs must be aligned with synchro body grooves.

• | Place synchro body assembly (1) on main shaft

• | Press synchro body in KM-473 on to main shaft

| Important: Retaining ring must engage completely

• | fit new retaining ring

43. Fit bearing support with rocker arm.

• | Insert 2x crosshead shoes (arrow) in 5th gear shift fork (3)

• | Insert bearing support with rocker arm in end shield

• | Insert 2x bolts with locking compound

• | Tighten 2x bolt

Tighten
Tighten 2x bolt 22 N·m (16 lb ft)

44. Install friction washer and magnet.

• | Fit friction washer (arrow) on axle, reverse gear wheel, with grease

• | Insert magnet with grease

| Important: Before installing end shield, check following items for position and seating:

40.1. | 3rd/4th gear shift fork

40.2. | 3rd/4th gear shift rod

40.3. | 5th gear shift driver

40.4. | 1st/2nd gear shift rod

40.5. | Lock pin for gear stop

40.6. | 1st/2nd gear shift fork

40.7. | Reverse gear shift fork

40.8. | Reverse gear shift rod

45. Detach end shield from KM-113-2 . Detach end shield from KM-552 .
46. Attach KM-6155 to transmission.
47. Stick new end shield gasket to transmission with roller bearing grease.

Important: Check that magnet (1) and friction washer (2) are correctly seated.

48. Install end shield (4).

• | Carefully insert end shield into transmission housing

• | Use new bolts

Tighten
Tighten 4x bolt (arrows) 22 N·m (16 lb ft)

49. Unscrew KM-6155 (3).

Important: Note close tolerance bolts.

50. Attach end shield cover.

• | Attach with new gasket to transmission housing

• | Tighten 4x bolt M7

Tighten
Tighten 4x bolt M7 15 N·m (11 lb ft)

• | Tighten 5x bolt M8

Tighten
Tighten 5x bolt M8 20 N·m (15 lb ft)

Important: Coat seal ring with grease.

51. Drive new seal ring with matching sleeve (1) flush into housing.
52. Push gearshift rod into gearbox cover and gearshift finger.

Important: Allow roll pin to protrude approximately 2 mm (0.0787 in)

53. Drive new roll pin into gearshift finger and gearshift rod.

Important: Gearshift finger must sit in gearbox intermediate lever.

54. Insert intermediate gearshift lever into gearbox cover.
55. Place washer (5), spring (4) and sleeve (3) on gearshift lever shaft.

Fit new retaining ring (2).

56. Attach gearbox cover to KM-982 .

Important: Guide bolt must sit in connecting link.

57. Drive guide bolt for connecting link (2) in gearbox cover.

Important: Do not damage engaging sleeve.

58. Drive engaging sleeve for intermediate shaft (1) with matching sleeve (3) into gearbox cover.
59. Detach gearbox cover from KM-982 .
60. Attach gearbox cover (1) to transmission.

• | Cement new gasket to transmission housing with grease

| Important: Adjusting pin must sit in adjusting bore and lock the gearbox.

• | Place gearbox cover on transmission

• | Tighten 4x bolt

Tighten
Tighten 4x bolt 15 N·m (11 lb ft)

• | Draw adjusting pin (2) out of adjusting bore

Important: Use new seal ring.

61. Fit reversing lamp switch (1).

Tighten reversing lamp switch (1).

Tighten
Tighten reversing lamp switch 20 N·m (15 lb ft)

62. Install new axle shaft seal ring.

• | Coat axle shaft seal ring with transmission fluid.

• | Install axle shaft seal ring flush in the transmission with KM-446 .

63. Install left engine damping block.

Tighten
Tighten 3x bolt 55 N·m (41 lb ft).

64. Detach transmission from KM-113-2 (1) using KM-6115 (2).
65. Detach transmission from KM-6115 .