Technical data
11 Gearbox identification
11.1 Gearbox identification
11.2 Code letters, assembly allocation, ratios, capacities
22 Rear final drive identification
32.1 Rear final drive identification
32.2 Code letters, assembly allocation, ratios, capacities
43 Transmission layout
53.1 Transmission layout
54 Calculating overall ratio (i)
74.1 Calculating overall ratio (i)
74.2 Notes on brake and performance tests and towing
75 General repair instructions
75.1 General repair instructions
7Clutch
91 Servicing clutch control
91.1 Servicing clutch control
91.2 Assembly overview - pedal cluster
101.3 Removing and installing over-centre spring
141.4 Removing and installing clutch pedal
151.5 Assembly overview - hydraulic system
171.6 Removing and installing master cylinder
201.7 Bleeding clutch system
222 Servicing clutch release mechanism
242.1 Servicing clutch release mechanism
243 Servicing clutch
273.1 Servicing clutch
27Controls, Housing
321 Servicing gear selector mechanism
321.1 Servicing gear selector mechanism
321.2 Installation position of gear selector mechanism
321.3 Removing and installing gear selector cables
351.4 Removing and installing gear stick housing
411.5 Servicing gear stick
431.6 Adjusting gear selector mechanism
462 Removing and installing gearbox
482.1 Removing and installing gearbox
482.2 Removing and installing gearbox and bevel box (Vehicles with 4 cylinder engine)
482.3 Removing and installing gearbox and bevel box (Vehicles with 6 cylinder fuel injection engine)
593 Removing and installing bevel box
703.1 Removing and installing bevel box
703.2 Removing and installing bevel box (Vehicles with 4-cylinder engine)
703.3 Removing and installing bevel box (Vehicles with 6-cylinder injection engine)
754 Checking oil in manual gearbox with bevel box
804.1 Checking oil in manual gearbox with bevel box
805 Dismantling and assembling gearbox
825.1 Dismantling and assembling gearbox
825.2 Removing and installing cover for gearbox housing and 5th gear
835.3 Removing and installing gearbox housing and selector mechanism
865.4 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
885.5 Dismantling and assembling sequence
906 Servicing gearbox housing and clutch housing
1076.1 Servicing gearbox housing and clutch housing
1077 Dismantling and assembling gearbox selector mechanism
1167.1 Dismantling and assembling gearbox selector mechanism
1168 Dismantling and assembling selector forks
1218.1 Dismantling and assembling selector forks
121Gears, Shafts
1271 Dismantling and assembling input shaft
1271.1 Dismantling and assembling input shaft
1272 Adjusting input shaft
1382.1 Adjusting input shaft
1382.2 Table of adjustment shims
1392.3 Carrying out check measurement
1413 Dismantling and assembling output shaft (pinion shaft)
1423.1 Dismantling and assembling output shaft (pinion shaft)
1424 Adjusting output shaft
1664.1 Adjusting output shaft
1665 Dismantling and assembling reverse shaft
1695.1 Dismantling and assembling reverse shaft
169Final drive, Differential rear
1731.2 Renewing left-hand flange shaft oil seal
1731.3 Renewing right-hand drive flange oil seal
1742 Renewing bevel box output flange oil seal (bevel box removed)
1752.1 Renewing bevel box output flange oil seal (bevel box removed)
1753 Dismantling and assembling differential
1773.1 Dismantling and assembling differential
1774 Adjustment overview
1894.1 Adjustment overview
1895 Adjusting differential
1895.1 Adjusting differential
1896 Dismantling and assembling bevel box
1916.1 Dismantling and assembling bevel box
1916.2 Assembly overview
1926.3 Dismantling and assembling sequence
2017 Adjusting shaft bevel gear and bevel gear (gear set)
2127.1 Adjusting shaft bevel gear and bevel gear (gear set)
2127.2 General notes
2127.3 Adjusting and marking of gear sets
2127.4 Position of shims
2137.5 Adjustment overview (bevel box)
2137.6 Recommended sequence for adjusting gear set
2147.7 Determining shim "S4" thickness when replacing output flange
2147.8 Adjusting shaft bevel gear
2157.9 Adjusting bevel gear
2218 Removing and installing propshaft
2248.1 Removing and installing propshaft
2249 Servicing propshaft
2289.1 Servicing propshaft
22810 Checking function of viscous coupling
23610.1 Checking function of viscous coupling
23611 Removing and installing viscous coupling
23611.1 Removing and installing viscous coupling
23612 Removing and installing viscous coupling seal
23812.1 Removing and installing viscous coupling seal
23813 Removing and installing drive flange oil seal (rear final drive)
23813.1 Removing and installing drive flange oil seal (rear final drive)
23814 Functional check of free-wheel
24014.1 Functional check of free-wheel
24015 Functional check of free-wheel lock
24015.1 Functional check of free-wheel lock
24016 Removing and installing rear final drive
24116.1 Removing and installing rear final drive
24117 Checking rear final drive oil
24417.1 Checking rear final drive oil
24418 Dismantling and assembling rear final drive
24518.1 Dismantling and assembling rear final drive
24518.2 Removing viscous coupling and rear axle housing from bevel gear housing
25718.3 Servicing shaft bevel gear bearings
25918.4 Pressing bevel gear off and on input shaft
26318.5 Servicing bevel gear/input shaft bearings
26418.6 Servicing differential bearings
26818.7 Installing rear axle housing on bevel gear housing and building on viscous coupling
27019 Dismantling and assembling differential and freewheel (assembly overview)
27519.1 Dismantling and assembling differential and freewheel (assembly overview)
27520 Dismantling and assembling differential (sequence)
27920.1 Dismantling and assembling differential (sequence)
27921 Removing and installing freewheel (sequence)
28021.1 Removing and installing freewheel (sequence)
28022 Dismantling and assembling freewheel (sequence)
28122.1 Dismantling and assembling freewheel (sequence)
28123 Adjusting bevel gear and shaft bevel gear (gear set)
28223.1 Adjusting bevel gear and shaft bevel gear (gear set)
28223.2 General notes
28223.3 Adjusting and marking of gear sets
28323.4 Position of shims
28423.5 Adjustment overview (rear final drive)
28423.6 Recommended sequence for adjusting gear set
28523.7 Adjusting shaft bevel gear
28523.8 Adjusting bevel gear
289