the stripdown
The first thing you will want to do is remove the gearbox selector unit, remove the 5 13mm bolts
after removal
After this you will need to remove 7 10mm bolts that hold the tin cover on at the end of the gearbox
Now you will have to knock out the locking tab on the nuts at the end of each of the shafts and take the nuts off
Now remove the 10mm bolt that holds the sector onto the selector shaft
With the bolts and nuts removed pop a screw driver under 2 sides of one of the gears and lift the gear off its splines
try not to lose the small springs and round rods that hold the selector in place
This picture shows where spring is round rod would be on the end of this
Now remove the 4 5mm counter sunk cap head bolts with the shake proof washers on them
and lift the plate off
Holding the bearing's in place is 2 spring clips, remove them
Now time to remove a total of 12 13mm bolts that hold the gear casing to the bell housing and a drive-shaft seal plate onto the differential housing
plate removed
o-ring on the back of the plate, one item to take note of
Now to remove the bolt for the reverse idler shaft (13mm)
then pull off the casing, trying to keep it level, you can tap the top of each shaft as the bearings would be sticking on abit and it will come straight off
remove the 2 13mm bolts that hold the reverse gear selector on
lift the reverse gear up slightly then turn the shaft and pull it up and it will come out
This is the reverse selector
This is the little bar that line the hole with the hole in casing for the reverse gear
you can now remove the selector unit for the man gears, nothing holding them on just lift up and pull out
Now you should have a gearbox like this
Simply pull both shafts out together and place them somewhere
lay shaft
main shaft
Now remove 4 13mm bolts and 4 15mm bolts that hold the differential unit on and remove from bell housing
arrow points out a magnet for collecting metal debris
The differential
from left to right (arrows)
spacer, bearing runner, tapered roller bearing
planet and sun gears
Full view off 2 differentials, both with bonded crown wheels, i was after a bolted
Hope this helps you
Ash