FINAL REASSEMBLY

Fit selector rod

Degrease the clamping bolt of the selector rod’s ‘claw’ and its threaded hole. Oil the rest of the rod and push it into place. Fit the claw and install its clamping bolt with thread-locking compound.

Install selector mechanism

Fit the mechanism. If you haven’t already done so, fit the clutch release shaft in the bellhousing – it’ll be easier with the input shaft not yet in place. Install the guide tube for the release bearing, if fitted.

Add major assemblies

Place the final drive in position. Take a firm hold of the input and output shafts, then roll them together to mesh the gears. Place carefully into their roller bearings, meshing the output and final drive.

Fit reverse gear

Tuck the reverse idler between the shafts and onto its selector, then push its shaft in place. Note the sun gears of the diff are free to turn and fall out. Beware of this when handling the transaxle.

Mount selector rods

Refit the selector forks and rods. You’ll have to do a bit of mutual wriggling of rod, fork, selector sleeve and gear selector to get each one right.

They should all slide into place without binding.

Replace casing

Oil the bearings and the components of the output shaft and diff. Replace the top of the casing. Use a new gasket and coat both sides with sealant. Insert the detent springs and balls with a little oil.

Secure shafts

Pull the shaft bearings as far out as possible with the casing horizontal. Tease the snap rings into their grooves. Hold the shaft while you run your finger around the ring and ease it into place.

Complete the shafts

Fit the fifth gear and selector assemblies. Leave the fork loose and engage fifth gear by hand. Engage any other gear with the selector to lock the ‘box. Torque the shaft end nuts and stake them.

Finish off

Finish reassembly by fitting the end cap and gasket, speedometer gear, etc. Recheck the casing nut torques. Install driveshaft cups, if fitted. If not, don’t fill it with oil until the shafts are inserted.