PRE-RELEASE

To dismantle

/ 9-3 (9440) / 2003 / 4. Transmission / Manual gearbox / 5-speed / Adjustment/replacement / To dismantle

To dismantle

The gearbox must be cleaned before dismantling.

Important
Holes for drive shafts and delivery line to the slave cylinder must be covered before cleaning the gearbox, use plugs for drive shaft holes 587 92 665.

After cleaning the outside of the gearbox, start work as follows

Mount the gearbox on a service stand with 87 92 228 Holder, transmission .

Detach the delivery line. Compress the sleeve on the inside using pliers and push the delivery line forward. Prise up the catch on the sleeve and press in the delivery pipe to detach it.

Undo the slave cylinder screws and remove it.

Remove the bolts for the reverse gear. Note the O-ring!

Remove the end plate. Mark where the ground screw is fitted. Remove the gasket.

Engage 1st gear to lock the gearbox. Refer to the shift arm positions in the illustration. Tap out the retention pin from the 5th gear selector fork.

Important
Before removing the synchromesh sleeve, mark its position relative to the 5th gear synchromesh with a pen to facilitate refitting.

Remove the fork and sleeve and then refit the sleeve.

Press down on the sleeve to engage 5th gear. Two gears must be engaged simultaneously while removing the nut on the output shaft.

It is essential that the sleeve is mounted on the synchromesh hub so that the 6 large gear teeth on the sleeve mesh with the 6 deep tooth gaps on the hub.

Knock away the nut lock with a drift on the nut for the output shaft.

Remove the nut.

Important
In all work which involves dismantling the gearbox, a new nut and a new clamping sleeve should be fitted on assembly as the old clamping sleeve will have lost its tension.

Remove the circlip for the 5th gear synchromesh hub. Carefully tap down the hub to make it easier. Lift off the sleeve and then use 87 91 287 Puller, 150 mm , 87 91 303 Arm, 150 mm and 87 92 640 Tool, 5 to lift the 5th gear synchromesh hub (use grease on the tip of the puller). Keep the leaf springs. Then lift up the pinion, baulk ring and needle bearing.

10.

Remove the 5th gear wheel with 87 92 566 Puller, 5 , 89 96 084 Puller, wheel hub and 87 91 410 Sleeve .

11.

Undo the bolts on the differential bearing support.

12.

Remove the bearing support and retain the shims.

13.

Remove the gear selector bracket.

14.

Undo the screw for the reverse shaft support in the gearcase.

15.

Undo and remove the bolts from the mating surface between the gearcase and the clutch housing. Tap down the 2 locating sleeves.

16.

Engage neutral gear.

17.

Fit two 87 92 129 Attachment eye, puller (x 2) . Fit 87 91 410 Sleeve to the output shaft journal. Hook 87 91 287 Puller, 150 mm with 87 91 303 Arm, 150 mm to the eyes and carefully pull off the housing until the pinion and bearing come loose from the shaft. Carefully tap loose the mating surface.

18.

Remove the tools. Lift away the gearcase.

Note
Put the preload washer on the selector shaft in a safe place.

19.

Tap out the differential bearing race. Use 87 92 202 Sleeve and 87 91 204 Sleeve, bearing race .

20.

Remove the reverse shaft and gear selector fork.

21.

Remove the reverse lever.

22.

Remove the bolt and lift the shifting mechanism slightly so that the locating sleeves come away from their seats. Lift away the sleeves.

Pull the selector mechanism back towards the differential and angle it out slightly. Lift out the selector mechanism.

23.

Lift the input shaft slightly and lift the reverse shaft and pinion (reverse gear).

24.

Lift off the 4th gear wheel. Leave the clamping sleeve on the shaft.

25.

Place 87 91 287 Puller, 150 mm with 87 91 303 Arm, 150 mm under the 1st gear wheel on the output shaft. Place 87 91 410 Sleeve as protection on the output shaft journal. Pull slightly and fit 87 92 103 Assembly fixture, 1 to hold together the 1st gear and 2nd gear synchromesh units. Fit a cable tie around the tool and the gear set. Pull up all the gear wheels on the output shaft about 15 mm.