Technical Note6036A

X06, and JB1 - X35, and JB1 or JB3 or JC5 -

X40, and JB0 or JB1 or JB3 or JB5 - X42, and
JB0 or JB1 or JB3 or JB5 - X44, and JB1 - X48,
and JB1 or JB3 - X53, and JB1 or JB3 or JB5 -
X56, and JB3 - X57, and JB0 or JB1 or JB3 or
JB5 - X64, and JB1 or JB3 or JC5 - X65, and JB1
or JB3 or JC5 - X66, and JC5 - X76, and JB1 or
JB3 or JC5, and RENAULT BRAND
JB1 - JB3 - JC5 manual gearboxes

TWINGO - TWINGO II - RENAULT 5 - EXPRESS - KANGOO -

CLIO - CLIO II - SYMBOL - THALIA - RENAULT 9 - RENAULT 19
- RENAULT 21 - MEGANE - LAGUNA - ESPACE III - AVANTIME

Edition 3
77 11 398 862 FEBRUARY 2009 Edition Anglaise

"The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
specifications current when it was prepared.
The reproduction or translation in part of whole of the present document, as well as the use
The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written
production of the various component units and accessories from which his vehicles are consent of Renault.
constructed."

© Renault s.a.s 2008

JB1 - JB3 - JC5 manual gearboxesContentsPage

JB1 - JB3 - JC5 manual gearboxes

Contents

Page

21A MANUAL GEARBOX 21A MANUAL GEARBOX

Manual gearbox: Precautions Manual gearbox differential

for repair 21A-1 bearing: Removal - Refitting 21A-59

Manual gearbox: 5th gear housing: Removal -

Specifications 21A-3 Refitting 21A-62

Manual gearbox: List and 5th gear sprockets and

location of components 21A-8 synchronisers: Removal -
Refitting 21A-63
Manual gearbox: Standard
exchange 21A-15

Manual gearbox: Repair 21A-16

Manual gearbox: Check 21A-18

Gearbox support equipment:

Use 21A-21

Mechanism cover: Removal -

Refitting 21A-22

Pressure plate housing

bearing: Removal - Refitting 21A-28

Gearbox shaft: Removal -

Refitting 21A-31

Output shaft: Stripping -

Rebuilding 21A-36

Gearbox shaft: Adjustment 21A-44

Clutch housing bearing:

Removal - Refitting 21A-48

Manual gearbox selector

shaft: Removal - Refitting 21A-51

Manual gearbox differential:

Removal - Refitting 21A-54
 MANUAL GEARBOX
Manual gearbox: Precautions for repair 21A
X06, and 5 SPEED MANUAL GBOX – X40, and 5 SPEED MANUAL GBOX – X44, and 5 SPEED MANUAL GBOX
– X56, and 5 SPEED MANUAL GBOX – X57, and 5 SPEED MANUAL GBOX – X64, and 5 SPEED MANUAL
GBOX – X65, and 5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX – X66, and 5 SPEED MANUAL GBOX
or 6 SPEED MANUAL GBOX – X76, and 5 SPEED MANUAL GBOX – X35, and 5 SPEED MANUAL GBOX

SAFETY Use professional products and apply them with care,

for example do not apply too much sealing paste to the
sealing surface to prevent damaging the component.
General information
This method provides information which will allow you
to: WARNING
Applying excess sealant could cause it to be squee-
- acquire good knowledge of the component on which
zed out when parts are tightened. A mixture of sea-
you will be working,
lant and fluid may cause damage to some
- benefit from the best repair conditions, components.

- obtain optimum component operation and meet cus- Observe the chronological order of the steps:
tomer requirements,
- remove the component,
- optimise component repair time.
- clean the component before repairing,
It is worth taking the time to read this method as you
- remove the part(s) concerned
will gain time later on during the repairs.
- check the part(s) removed,
a - General recommendations - replace faulty part(s) with new part(s),

Observe basic principles of vehicle repair. - perform the necessary adjustments and/or settings so
that the component operates correctly,
The quality of repair depends first and foremost on the
care exercised by the person in carrying it out. - observe the tightening torques.

Carry out the operation on the component on a clean

working area. Note:
To ensure good repair: Ensure you use the correct type of bearing for the
gearbox. There are three types of bearing for diffe-
- use the recommended consumables (see Vehicle:
rent gearbox suffixes (NTN - SNR - TIMKEN). They
Parts and ingredients for the repairwork) ,
are not interchangeable.
- use the recommended tools,
- observe the tightening torques,
Note:
- observe the recommendations for parts that should
always be replaced after removal, refitting or replace- Ensure sure that the parts removed match up and
ment operations, ensure that they are refitted in the correct order.
- clean and degrease the sections to be bonded, to en-
sure they bond correctly. b - Special tooling
Use suitable tools which are in good condition (use of
WARNING « multi-purpose » tools, such as adjustable pliers, etc.,
should be avoided wherever possible).
To ensure proper sealing, the gasket surfaces must
be clean, dry and not greasy (avoid any finger For good quality repairs and for working in safe condi-
marks). tions, use only special tooling.

c - Safety
WARNING Equipment risks:
Do not scrape the joint faces of the aluminium, any - The "Note" heading used in the description of the
damage caused to the joint face will result in a risk method indicates that particular care should be taken
of leaks. for the operation described.

21A-1
 MANUAL GEARBOX
Manual gearbox: Precautions for repair 21A
X06, and 5 SPEED MANUAL GBOX – X40, and 5 SPEED MANUAL GBOX – X44, and 5 SPEED MANUAL GBOX
– X56, and 5 SPEED MANUAL GBOX – X57, and 5 SPEED MANUAL GBOX – X64, and 5 SPEED MANUAL
GBOX – X65, and 5 SPEED MANUAL GBOX or 6 SPEED MANUAL GBOX – X66, and 5 SPEED MANUAL GBOX
or 6 SPEED MANUAL GBOX – X76, and 5 SPEED MANUAL GBOX – X35, and 5 SPEED MANUAL GBOX

- The "Important" heading used in the description of the

method indicates that there is a risk of damage to the
component.
Working safely:
- The "Warning" heading used in the description of the
method indicates that particular care should be taken
for the operation described and that there is a human
risk,
- use supports and adopt a correct posture when per-
forming heavy work or raising loads,
- check that the working area is clean and tidy during
the operation,
- use personal protection (gloves, goggles, work
shoes, masks, skin protection, etc.),
- do not use harmful products in unventilated rooms,
- do not ingest any chemicals (brake fluid, coolant,
etc.).
Respecting the environment:
- sort waste according to its particular qualities,
- do not burn discarded products (tyres, etc.).

d - Conclusion
Respecting the recommended methods will guarantee
the best performance and reliability of the component.

21A-2
 MANUAL GEARBOX
Manual gearbox: Specifications 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
I - IDENTIFICATION

19860
A marking (1) on the gearbox casing indicates:
- (A) Gearbox type
- (B) Gearbox suffix
- (C) Fabrication number
109167
- (D) Factory of manufacture

II - GEAR RATIOS

Suffix 1st 2nd 3rd 4th 5th Final Reverse Tachometer

drive gear

JB0

JB0-017 11/41 21/43 28/37 31/28 - 16/57 11/39 21/19

JB0-019 11/41 21/43 28/37 31/28 - 15/56 11/39 21/19

JB0-020 11/41 21/43 28/37 31/28 - 19/59 11/39 21/20

JB0-021 11/41 21/43 28/37 31/28 - 14/59 11/39 21/19

JB0-022 11/41 21/43 28/37 31/28 - 14/63 11/39 21/19

JB0-023 11/41 21/43 28/37 31/28 - 15/58 11/39 21/19

JB0-024 11/41 21/43 28/37 31/28 - 16/57 11/39 21/19

JB0-028 11/41 21/43 28/37 31/28 - 15/58 11/39 21/20

JB0-029 11/41 21/43 28/37 31/28 - 17/56 11/39 21/20

JB0-030 11/41 21/43 28/37 31/28 - 16/57 11/39 21/20

JB0-031 11/41 21/43 28/37 31/28 - 16/55 11/39 21/20

JB0-032 11/41 21/43 28/37 31/28 - 16/57 11/39 21/20

JB0-033 11/41 21/43 28/37 31/28 - 15/58 11/39 21/19

JB0-034 11/41 21/43 28/37 31/28 - 16/57 11/39 21/19

21A-3
 MANUAL GEARBOX
Manual gearbox: Specifications 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

Suffix 1st 2nd 3rd 4th 5th Final Reverse Tachometer

drive gear

JB0-035 11/41 21/43 28/37 31/28 - 15/61 11/39 21/19

JB0-036 11/41 21/43 28/37 31/28 - 15/61 11/39 21/20

JB0-040 11/41 21/43 28/37 31/28 - 17/56 11/39 21/19

JB0-041 11/41 21/43 28/37 31/28 - 17/56 11/39 21/19

JB1

JB1-510 11/37 22/41 28/37 34/35 39/32 15/61 11/39 -

JB1-511 11/41 21/43 28/37 30/29 39/31 14/63 11/39 21/19

JB1-513 11/37 22/41 28/37 34/35 39/32 14/59 11/39 -

JB1-514 11/37 22/41 28/37 34/35 39/32 15/61 11/39 -

JB1-515 11/41 21/43 28/39 34/35 39/32 14/63 11/39 -

JB1-517 11/37 22/41 28/37 30/29 39/32 15/58 11/39 -

JB1-518 11/37 22/41 28/37 34/35 39/32 15/61 11/39 -

JB1-519 11/37 22/41 28/37 34/35 39/32 15/61 11/39 -

JB1-520 11/37 22/41 28/37 34/35 39/32 15/61 11/39 -

JB1-521 11/37 22/41 28/37 30/29 42/31 14/63 11/39 -

JB1-523 11/37 22/41 28/37 30/29 42/31 14/63 11/39 -

JB1-524 11/41 21/43 28/39 34/35 39/31 16/57 11/39 -

JB1-525 11/41 21/43 28/39 34/35 39/31 16/57 11/39 -

JB1-926 11/41 21/43 28/37 30/29 39/31 14/59 11/39 21/19

JB1-939 11/41 21/43 28/37 30/29 39/31 15/61 11/39 21/19

JB1-940 11/37 22/41 28/37 30/29 41/31 15/56 11/39 21/20

JB1-941 11/37 22/41 28/37 30/29 39/32 15/58 11/39 21/20

JB1-956 11/41 21/43 28/37 30/29 39/31 14/69 11/39 21/19

JB1-962 11/41 21/43 28/37 30/29 41/31 15/56 11/39 -

JB1-967 11/37 22/41 28/37 34/35 39/31 16/55 11/39 21/19

JB1-968 11/37 22/41 28/37 34/35 39/31 16/57 11/39 21/19

JB1-969 11/41 21/43 28/39 34/35 39/31 16/55 11/39 21/19

JB1-970 11/41 21/43 28/39 34/35 37/33 15/58 11/39 21/18

JB1-974 11/41 21/43 28/39 34/35 37/33 16/57 11/39 21/19

JB1-977 11/41 21/43 28/39 34/35 39/32 16/55 11/39 21/19

21A-4
 MANUAL GEARBOX
Manual gearbox: Specifications 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

Suffix 1st 2nd 3rd 4th 5th Final Reverse Tachometer

drive gear

JB1-985 11/41 21/43 28/39 34/35 39/32 14/63 11/39 21/18

JB1-988 11/37 22/41 28/37 30/29 41/31 15/56 11/39 21/19

JB1-989 11/37 22/41 28/37 30/29 39/32 15/58 11/39 21/19

JB1-990 11/41 21/43 28/37 30/29 39/31 14/69 11/39 21/19

JB1-991 11/37 22/41 28/37 34/35 39/32 15/61 11/39 21/19

JB1-992 11/41 21/43 28/39 34/35 39/32 14/69 11/39 21/18

JB1-994 11/41 21/43 28/39 34/35 39/32 14/59 11/39 21/19

JB1-996 11/37 22/41 28/37 34/35 39/32 15/61 11/39 21/19

JB1-997 11/37 22/41 28/37 34/35 39/32 14/59 11/39 21/19

JB1-999 11/41 21/43 28/39 34/35 39/31 14/69 11/39 21/19

JB3

JB3-905 11/37 22/41 28/37 30/29 41/31 16/55 11/39 21/19

JB3-938 11/37 22/41 28/37 30/29 42/31 15/58 11/39 -

JB3-949 11/41 21/43 28/39 34/35 39/32 14/59 11/39 -

JB3-952 11/41 21/43 28/39 34/35 39/32 15/58 11/39 -

JB3-953 11/37 22/41 28/37 34/35 39/32 15/61 11/39 -

JB3-954 11/41 21/43 28/37 30/29 39/31 15/61 11/39 -

JB3-955 11/41 21/43 28/39 34/35 39/32 14/59 11/39 -

JB3-956 11/37 22/41 28/37 34/35 39/32 14/59 11/39 -

JB3-957 11/41 21/43 28/39 34/35 39/32 14/59 11/39 22/18

JB3-958 11/37 22/41 28/37 34/35 39/32 15/61 11/39 21/19

JB3-960 11/41 21/43 28/39 34/35 39/32 14/59 11/39 21/19

JB3-961 11/41 21/43 28/39 34/35 39/32 15/61 11/39 21/18

JB3-967 11/37 22/41 28/37 34/35 39/32 15/61 11/39 -

JB3-969 11/37 22/41 28/37 30/29 42/31 16/57 11/39 21/19

JB3-970 11/37 22/41 28/37 30/29 41/31 14/59 11/39 21/19

JB3-971 11/41 21/43 28/37 30/29 39/31 14/59 11/39 21/19

JB3-972 11/37 22/41 28/37 30/29 42/31 16/57 11/39 -

JB3-973 11/37 22/41 28/37 34/35 39/31 15/61 11/39 -

JB3-974 11/37 22/41 28/37 30/29 41/31 15/58 11/39 21/19

21A-5
 MANUAL GEARBOX
Manual gearbox: Specifications 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

Suffix 1st 2nd 3rd 4th 5th Final Reverse Tachometer

drive gear

JB3-975 11/41 21/43 28/37 30/29 41/31 14/63 11/39 21/19

JB3-976 11/41 21/43 28/39 34/35 39/31 16/57 11/39 21/18

JB3-979 11/37 22/41 28/37 34/35 39/32 15/61 11/39 -

JB3-980 11/37 22/41 28/37 30/29 42/31 16/57 11/39 -

JB3-981 11/41 21/43 28/39 34/35 39/32 14/59 11/39 -

JB3-982 11/37 22/41 28/37 34/35 39/32 14/59 11/39 -

JB3-983 11/37 22/41 28/37 30/29 42/31 15/58 11/39 -

JB3-984 11/37 22/41 28/37 34/35 39/32 15/61 11/39 -

JB3-985 11/37 22/41 28/37 34/35 39/32 15/61 11/39 -

JB3-986 11/37 22/41 28/37 30/29 41/31 16/55 11/39 -

JB3-987 11/41 21/43 28/37 30/29 41/31 14/63 11/39 21/18

JB3-988 11/37 22/41 28/37 30/29 42/31 16/57 11/39 21/18

JB3-989 11/41 21/43 28/39 34/35 39/32 14/59 11/39 21/18

JB3-990 11/41 21/43 28/37 30/29 41/31 14/63 11/39 -

JB3-991 11/37 22/41 28/37 34/35 39/32 14/59 11/39 -

JB3-992 11/37 22/41 28/37 30/29 42/31 16/57 11/39 -

JB3-995 11/41 21/43 28/37 30/29 41/31 14/59 11/39 -

JB5

JB5-000 11/41 19/39 25/33 30/29 34/27 15/61 11/39 21/19

JB5-001 11/41 19/39 25/33 30/29 34/27 16/55 11/39 21/20

JB5-002 11/34 19/35 25/33 30/29 33/25 15/61 11/39 21/20

JB5-003 11/41 19/39 25/33 30/29 34/27 17/56 11/39 21/20

JB5-004 11/41 19/39 25/33 30/29 34/27 15/61 11/39 21/20

JB5-005 11/41 19/39 25/33 30/29 34/27 16/57 11/39 21/20

JB5-006 11/41 19/39 25/33 30/29 34/27 16/57 11/39 21/20

JB5-007 11/41 19/39 25/33 30/29 34/27 15/58 11/39 21/19

JB5-008 11/41 19/39 25/33 30/29 34/27 15/58 11/39 21/20

JB5-009 11/41 19/39 25/33 30/29 34/27 15/61 11/39 21/19

JB5-010 11/41 19/39 25/33 30/29 34/27 15/57 11/39 21/20

JB5-015 11/41 19/39 25/33 30/29 34/27 14/59 11/39 21/20

21A-6
 MANUAL GEARBOX
Manual gearbox: Specifications 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

Suffix 1st 2nd 3rd 4th 5th Final Reverse Tachometer

drive gear

JC5

JC5-062 11/37 22/41 28/37 34/35 39/31 15/61 11/39 21/18

JC5-070 11/41 21/43 28/37 35/34 39/31 15/61 11/39 22/18

JC5-089 11/34 22/41 28/37 34/35 39/31 15/58 11/39 21/19

JC5-090 11/37 22/41 28/37 34/35 39/32 15/58 11/39 -

JC5-100 11/41 21/43 28/39 31/34 39/32 15/58 11/39 -

JC5-103 11/41 21/43 28/37 35/34 42/31 15/56 11/39 22/18

JC5-106 11/41 21/43 28/39 31/34 37/33 16/57 11/39 -

JC5-107 11/41 21/43 28/37 35/34 42/31 17/56 11/39 -

JC5-108 11/37 22/41 28/37 34/35 39/32 15/61 11/39 -

JC5-109 11/41 21/43 28/37 35/34 42/31 15/56 11/39 -

JC5-119 11/41 21/43 28/37 35/34 39/31 15/61 11/39 -

JC5-120 11/41 21/43 28/37 35/34 42/31 15/58 11/39 -

JC5-125 11/37 22/41 28/37 35/34 41/31 15/58 11/39 21/19

JC5-126 11/41 21/43 28/37 35/34 41/31 16/57 11/39 21/19

JC5-128 11/41 21/43 28/37 35/34 41/31 17/56 11/39 21/19

JC5-129 11/34 22/41 28/37 34/35 39/31 15/61 11/39 21/19

JC5-130 11/34 22/41 28/37 34/35 39/31 15/61 11/39 -

JC5-131 11/37 22/41 28/37 34/35 39/32 15/58 11/39 -

JC5-132 11/41 21/43 28/37 35/34 41/31 16/57 11/39 -

JC5-137 11/37 22/41 28/37 34/35 39/32 15/61 11/39 -

JC5-138 11/41 `21/43 28/37 35/34 42/31 17/56 11/39 -

JC5-140 11/41 21/43 28/37 35/34 41/31 17/56 11/39 -

JC5-144 11/41 21/43 28/37 35/34 41/31 17/56 11/39 21/19

21A-7
 MANUAL GEARBOX
Manual gearbox: List and location of components 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

X06 – X35, and JB1 or JB3 – X40 – X42 – X44 –

X48 – X53 – X56 – X57 – X64, and JB1 or JB3 –
X65, and JB1 or JB3 – X76, and JB1 or JB3

101388
(17) Lock ring
(1) Oil deflector
(18) Third-fourth synchroniser hub
(2) Output shaft bearing
(19) Synchroniser ring
(3) Output shaft
(20) Fourth idle gear
(4) First idle gear
(21) Lock washer
(5) Synchroniser ring
(22) Bearing retaining clips on
(6) First-second synchroniser hub mechanism housing
(7) Synchroniser ring (23) Output shaft bearing
(8) Lock ring (24) Fifth fixed gear
(9) Splined washer (25) Output shaft bolt
(10) Second idle gear (26) Input shaft bearing
(11) Splined washer (27) Primary shaft
(12) Lock ring (28) Bearing retaining clips on
(13) Splined washer mechanism housing
(14) Third idle gear (29) Input shaft bearing
(15) Synchroniser ring (30) Lock washer
(16) Splined washer (31) Ring under fifth idle gear

21A-8
 MANUAL GEARBOX
Manual gearbox: List and location of components 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

(32) Fifth idle gear (40) Synchroniser ring

(33) Synchroniser ring (41) Retaining washer
(34) Synchroniser spring (42) Input shaft nut
(35) Fifth gear synchroniser hub
(36) Synchroniser spring
(37) Friction cone
(38) Retaining washer X35, and JC5 – X64, and JC5 – X65, and JC5 –
(39) Input shaft nut X66 – X76, and JC5

141104
(53) Synchroniser spring
(43) Input shaft bearing
(54) Assembled 5th gear synchroni-
(44) Clutch shaft bearing ser hub
(45) Pr imary shaft (55) Input shaft self-locking nut
(46) Adjusting shim (56) Retaining washer
(47) Bearing retaining clips on (57) Input shaft nut
mechanism housing
(48) Input shaft bearing
(49) Lock washer
(50) Ring under fifth idle gear
(51) Fifth gear pinion
(52) Synchroniser ring

21A-9
 MANUAL GEARBOX
Manual gearbox: List and location of components 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

X35, and JC5 – X64, and JC5 – X65, and JC5 –

X66 – X76, and JC5

141105
(75) Adjusting shim
(58) First idle gear
(76) Input shaft bearing
(59) Synchroniser ring
(77) Fifth idle gear
(60) Synchroniser spring
(78) Output shaft bolt
(61) First gear synchroniser hub
(62) Synchroniser spring
(63) Synchroniser ring
(64) Spacer ring
(65) Second idle gear
(66) Triple-cone synchroniser rings
(67) Splined washer
(68) Ring under third idle gear
(69) Third idle gear
(70) Synchromesh ring
(71) Reverse gear sprocket
(72) Synchromesh ring
(73) Ring under fourth idle gear
(74) Fourth idle gear

21A-10
 MANUAL GEARBOX
Manual gearbox: List and location of components 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

141102

(79) Clutch control fork

(80) Fork pivot ball joint
(81) Pivot gaiter
(82) Assembled reverse gear shaft
(83) Bearing ring
(84) Assembled 1-2 fork shaft claw
(85) Assembled 3-4 fork shaft claw
(86) Reverse gear guide
(87) Assembled 5th gear fork shaft
(88) Lip seal
(89) Gaiter
(90) Tie-bar
(91) Gaiter
(92) Shaft lever and finger assembly
(93) Thickness washer
(94) 5th gear kickdown point
(95) Gaiter
(96) Ball joint bearing shell
(97) Lock ring
(98) Return spring

21A-11
 MANUAL GEARBOX
Manual gearbox: List and location of components 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

141103

(99) Support bracket

(100) Gaiter
(101) Clutch protection component
(102) Clutch guide tube
(103) Clutch housing
(104) Oil collector
(105) Oil supply channel
(106) Filler plug
(107) Mechanism housing
(108) 5th gear cover seal
(109) Breather vent body
(110) Breather pipe
(111) Union
(112) Breather
(113) 5th gear cover

21A-12
 MANUAL GEARBOX
Manual gearbox: List and location of components 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

X06 – X35, and JB1 or JB3 – X40 – X42 – X44 –

X48 – X53 – X56 – X57 – X64, and JB1 or JB3 –
X65, and JB1 or JB3 – X76, and JB1 or JB3

141101
(130) Assembled differential mecha-
(114) O-ring nism
(115) Lip seal (131) Hollow sun wheel
(116) Lock ring (132) Thrust washer
(117) Ball bearing (133) Stop washer
(118) Lock ring
(119) Lip seal
(120) Differential line tightening nut
(121) Adjusting shim
(122) Roller bearing
(123) Tachometer control ring
(124) Tachometer control pinion
(125) Tachometer pinion shaft
(126) Locking pin
(127) Ball bearing
(128) Washer
(129) Spring washer

21A-13
 MANUAL GEARBOX
Manual gearbox: List and location of components 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

X35, and JC5 – X64, and JC5 – X65, and JC5 –

X66 – X76, and JC5

141100

(134) O-ring
(135) Lip seal
(136) Differential line securing nut
(137) Adjusting shim
(138) Roller bearing
(139) Tachometer control bolt
(140) Tachometer target
(141) Tachometer control pinion
(142) Tachometer shaft
(143) Locking pin
(144) Roller bearing
(145) Assembled differential mecha-
nism
(146) Hollow sun wheel
(147) Thr ust washer
(148) Lock ring

21A-14
 MANUAL GEARBOX
Manual gearbox: Standard exchange 21A
X06 – X35, and JB1 or JB3 – X40, and JB1 or JB3 or JB5 – X42, and JB1 or JB3 or JB5 – X44 – X48 – X53 – X56
– X57, and JB1 or JB3 or JB5 – X64 – X65 – X76, and JB3 or JC5 – X66
I - OPERATION FOR REMOVAL OF PART a Refit on the standard replacement gearbox (see
CONCERNED 21A, Manual gearbox, Mechanism cover: Remo-
val - Refitting, page 21A-22) :
a Remove the manual gearbox (see Manual gear-
box: Removal - Refitting) . - the reverse gear switch,
a Torque tighten (see 21A, Manual gearbox, Mecha-
nism cover: Removal - Refitting, page 21A-22) :
II - PREPARATION FOR RETURNING THE OLD
GEARBOX - the reverse gear switch,

a Drain the residual oil from the old gearbox.

a Check that the centring dowelsare in place.
a Clean the manual gearbox using the SURFACE
CLEANER (see Vehicle: Parts and ingredients a Refit the manual gearbox (see Manual gearbox:
for the repairwork) (04B, Consumables - Pro- Removal - Refitting) .
ducts). a Remove the elastic retaining strap from the gear le-
ver control.
a Remove the following parts from the old gearbox
(see 21A, Manual gearbox, Mechanism cover: a
Removal - Refitting, page 21A-22) :
Note:
- the reverse gear switch, Refitting the driveshafts requires special care, so
it is essential to consult the procedure.
- the centring pins,
a Refit the driveshafts (see Front right-hand wheel
a Remove the blanking cover caps from the standard
driveshaft: Removal - Refitting) and (see Front
gearbox to put them on the old gearbox.
left-hand wheel driveshaft: Removal - Refitting) .
a Secure the old gearbox on the base plate under the a Fill the gearbox (see Manual gearbox oil: Draining
same conditions as the standard replacement gear- - Refilling) .
box.

III - REFITTING OPERATION FOR PART

CONCERNED

WARNING
Failure to observe the following procedure could
cause irreparable damage to the manual gear-
box. ]

Note:
The gearbox is supplied with the third gear enga-
ged. The gear control lever is held in place on the
gearbox by an elastic retaining strap.
Any handling of the gearbox must be made with
the third gear engaged.
Any impact to the gearbox during handling may
cause the gearbox to lock if the third gear is not
engaged.

a Take the necessary precautions for refitting the

gearbox (see 21A, Manual gearbox, Manual gear-
box: Precautions for repair, page 21A-1)

21A-15
 MANUAL GEARBOX
Manual gearbox: Repair 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
- the bearings of the mechanism housing (see 21A,
Manual gearbox, Pressure plate housing bea-
IMPORTANT ring: Removal - Refitting, page 21A-28) ,
To avoid all risk of damage to the systems, apply - the bearings of the clutch housing (see 21A, Ma-
the safety and cleanliness instructions and opera- nual gearbox, Clutch housing bearing: Remo-
tion recommendations before carrying out any val - Refitting, page 21A-48) ,
repair (see 21A, Manual gearbox, Manual gear-
box: Precautions for repair, page 21A-1) . - the manual gearbox selector shaft (see 21A, Ma-
nual gearbox, Manual gearbox selector shaft:
Removal - Refitting, page 21A-51) .
REMOVAL
REFITTING
I - REPAIR PREPARATION OPERATION
I - REFITTING PREPARATION OPERATION
a Remove the gearbox (see Manual gearbox: Remo-
val - Refitting) . a Clean all the removed parts (see 21A, Manual gear-
box, Manual gearbox: Precautions for repair,
a Position the gearbox on the component support (see page 21A-1) .
21A, Manual gearbox, Gearbox support equip-
ment: Use, page 21A-21) . a Replace worn or damaged parts.
a Parts always to be replaced:
II - REMOVAL OPERATION. - the lip seals,

a Remove: - the O-rings,

- the fifth gear housing (see 21A, Manual gearbox, - the clutch thrust bearing guide,
5th gear housing: Removal - Refitting, page - the gear lock rings,
21A-62) ,
- the roll pins,
- the fifth gear synchroniser and pinions (see 21A,
- the input and output shaft bearing circlips,
Manual gearbox, 5th gear sprockets and syn-
chronisers: Removal - Refitting, page 21A-63) , - the synchroniser hub springs,

- the mechanism housing (see 21A, Manual gear- - the removed bearings,
box, Mechanism cover: Removal - Refitting, - the selector shaft rings,
page 21A-22) ,
- the spy seals,
- the gearbox shafts (see 21A, Manual gearbox,
Gearbox shaft: Removal - Refitting, page 21A- - the hydraulic clutch thrust bearing (if equipped),
31) , - the magnet.
- the differential (see 21A, Manual gearbox, Ma-
nual gearbox differential: Removal - Refitting, II - REFITTING OPERATION
page 21A-54) .
a Refit:
- the gearbox selector shaft (see 21A, Manual gear-
III - REPAIR OPERATION box, Manual gearbox selector shaft: Removal -
Refitting, page 21A-51) ,
a Strip down the output shaft (see 21A, Manual gear-
box, Output shaft: Stripping - Rebuilding, page - the bearings of the clutch housing (see 21A, Ma-
21A-36) . nual gearbox, Clutch housing bearing: Remo-
val - Refitting, page 21A-48) ,
a Check the shafts (see 21A, Manual gearbox, Ma-
nual gearbox: Check, page 21A-18) . - the bearings of the mechanism housing (see 21A,
Manual gearbox, Pressure plate housing bea-
a Remove: ring: Removal - Refitting, page 21A-28) ,
- the differential bearings (see 21A, Manual gear- - the differential bearings (see 21A, Manual gear-
box, Manual gearbox differential bearing: Re- box, Manual gearbox differential bearing: Re-
moval - Refitting, page 21A-59) , moval - Refitting, page 21A-59) ,

21A-16
 MANUAL GEARBOX
Manual gearbox: Repair 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
- the differential (see 21A, Manual gearbox, Ma-
nual gearbox differential: Removal - Refitting,
page 21A-54) .
a Rebuild the output shaft (see 21A, Manual gear-
box, Output shaft: Stripping - Rebuilding, page
21A-36) .
a Refit:
- the gearbox shafts (see 21A, Manual gearbox,
Gearbox shaft: Removal - Refitting, page 21A-
31) ,
- the mechanism housing (see 21A, Manual gear-
box, Mechanism cover: Removal - Refitting,
page 21A-22) ,
- the fifth gear synchroniser and pinions (see 21A,
Manual gearbox, 5th gear sprockets and syn-
chronisers: Removal - Refitting, page 21A-63) ,
- the fifth gear housing (see 21A, Manual gearbox,
5th gear housing: Removal - Refitting, page
21A-62) .

III - FINAL OPERATION

a Remove the gearbox from the component support
(see 2 1 A , Manual gearbox, Gearbox support
equipment: Use, page 21A-21) .
a Refit the gearbox (see Manual gearbox: Removal -
Refitting) .

21A-17
 MANUAL GEARBOX
Manual gearbox: Check 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
II - TEST OPERATION

IMPORTANT
1 - Gearing
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 21A, Manual gearbox, Manual gear-
box: Precautions for repair, page 21A-1) .

I - PREPARATION OPERATION FOR CHECK

Remove the gearbox (see Manual gearbox: Removal
- Refitting) .
Position the gearbox on the component support (see
21A, Manual gearbox, Gearbox support equipment:
Use, page 21A-21) .
Remove:
- the mechanism housing (see 21A, Manual gearbox,
Mechanism cover: Removal - Refitting, page 21A-
22) ,
- the gearbox shafts (see 2 1 A , Manual gearbox,
Gearbox shaft: Removal - Refitting, page 21A-31) ,
100413
- the differential (see 21A, Manual gearbox, Manual
gearbox differential: Removal - Refitting, page When checking, make sure that you pay particular at-
21A-54) . tention to the appearance of the teeth, especially that
of the chamfers and claws.
Strip down the output shaft (see 21A, Manual gear-
box, Output shaft: Stripping - Rebuilding, page Check that:
21A-36) . - the teeth (1) are not broken or chipped,
Before any checks, clean the parts concerned (see - the dogs (2) are not broken, chipped or worn,
21A, Manual gearbox, Manual gearbox: Precau-
tions for repair, page 21A-1) . - the friction cone (3) shows no sign of scratches or
blue stains,
- the inner wall (4) shows no sign of sticking or wear.

21A-18
 MANUAL GEARBOX
Manual gearbox: Check 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
2 - Synchroniser hub 3 - Synchroniser ring

141207 100414

Check that the dog teeth (7) show no sign of wear or

any fractures.

To check that the synchroniser ring is working correct-

ly, push the ring on the friction cone and rotate (8) : the
ring should not turn. Otherwise, replace the synchroni-
ser ring.

4 - Bearings

140935
Check:
- the selector rod slides into the hub without any pro-
blem,
- the synchroniser rollers (5) are in good condition,
- the synchroniser springs (6) are in good condition.

100411

Check:
- the bearings rotate correctly,

21A-19
 MANUAL GEARBOX
Manual gearbox: Check 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
- the lateral play.
If a bearing rotates unevenly or noisily, it must be repla-
ced.

III - FINAL OPERATION

Rebuild the output shaft (see 21A, Manual gearbox,
Output shaft: Stripping - Rebuilding, page 21A-36) .
Adjust the shafts (see 21A, Manual gearbox, Gear-
box shaft: Adjustment, page 21A-44) .
Refit:
- the differential (see 21A, Manual gearbox, Manual
gearbox differential: Removal - Refitting, page
21A-54) ,
- the gearbox shafts (see 2 1 A , Manual gearbox,
Gearbox shaft: Removal - Refitting, page 21A-31) ,
- the mechanism housing (see 21A, Manual gearbox,
Mechanism cover: Removal - Refitting, page 21A-
22) .
Remove the gearbox from the component support (see
21A, Manual gearbox, Gearbox support equipment:
Use, page 21A-21) .
Refit the gearbox (see Manual gearbox: Removal -
Refitting) .

21A-20
 MANUAL GEARBOX
Gearbox support equipment: Use 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

Essential special tooling

Bvi. 1581 Support for all types of J

gearboxes.

Essential equipment

component support

I - PREPARATION OPERATION FOR FITTING THE

GEARBOX ON THE COMPONENT SUPPORT
a

IMPORTANT
117504
To work on the gearbox in complete safety, it is
a Position the gearbox on the component support
essential to use a component support
using the workshop hoist.
a Remove the gearbox (see Manual gearbox: Remo- a Secure the gearbox on the gearbox support plate
val - Refitting) using bolts and nuts.

II - OPERATION FOR REMOVING THE GEARBOX

FROM THE COMPONENT SUPPORT
a Remove the bolts and nuts from the gearbox support
plate.
a Separate the gearbox from the component support
using the workshop hoist.

III - FINAL OPERATION

a Refit the gearbox (see Manual gearbox: Removal -
Refitting)

117503
a Fit the gearbox mounting plate (Bvi. 1581) (2) on
component support (1) using the retaining rods (3)
.

21A-21
 MANUAL GEARBOX
Mechanism cover: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
II - REMOVAL OPERATION FOR THE MECHANISM
Essential special tooling HOUSING
Bvi. 1570 Tools for fitting selector fork
shaft locking systems.

Tightening torquesm

mechanism housing 25 N.m

bolts

fifth gear kickdown point 20 N.m

IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 21A, Manual gearbox, Manual gear-
box: Precautions for repair, page 21A-1) .

REMOVAL 92957

a Remove the fifth gear kickdown point (1) .

I - REMOVAL PREPARATION OPERATION
a Remove the gearbox (see Manual gearbox: Remo-
Note:
val - Refitting) .
When removing the fifth gear kickdown point,
a Position the gearbox on the component support (see
recover one or both of the 0.30mm washers.
21A, Manual gearbox, Gearbox support equip-
ment: Use, page 21A-21) .
a Remove the bolts from the mechanism housing.
a Remove:
- the fifth gear housing (see 21A, Manual gearbox,
5th gear housing: Removal - Refitting, page
21A-62) ,
- the fifth gear synchroniser and pinions (see 21A,
Manual gearbox, 5th gear sprockets and syn-
chronisers: Removal - Refitting, page 21A-63) .

121188

a Remove the clip (2) from the reverse gear locating

ball and recover the spring (4) and the ball (3) .

21A-22
 MANUAL GEARBOX
Mechanism cover: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

93065

141129

a Remove the reverse gear switch (6) .

a Detach and remove the mechanism housing

upwards.

REFITTING

I - REFITTING PREPARATION OPERATION

a Clean the joint faces of the mechanism housing

using SUPER CLEANING AGENT FOR JOINT FA-
CES (see Vehicle: Parts and ingredients for the
121188 repairwork) (04B, Consumables - Products).
a Position two magnets or block the openings (5) to re-
cover the balls and retaining springs of the shafts.
WARNING
Do not scrape the joint faces of the aluminium,
any damage caused to the joint face will result in
a risk of leaks.

a Remove the residue using a plastic spatula.

a Finish cleaning the joint faces using a GREY ABRA-

SIVE PAD (see Vehicle: Parts and ingredients
for the repairwork) (04B, Consumables - Pro-
ducts).

WARNING
To ensure proper sealing, the gasket surfaces
must be clean, dry and not greasy (avoid any fin-
ger marks).

21A-23
 MANUAL GEARBOX
Mechanism cover: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
a Use SURFACE CLEANER (see Vehicle: Parts a Apply a bead of SEALING RESIN (see Vehicle:
and ingredients for the repairwork) to clean: Parts and ingredients for the repairwork) (04B,
Consumables - Products) to the joint face.
- the joint face of the mechanism housing and the
clutch housing,
- the mechanism housing.
a Parts always to be replaced:
- the lip seals,
- the O-rings,
- the clutch thrust bearing guide,
- the gear lock rings,
- the roll pins,
- the input and output shaft bearing circlips,
- the synchroniser hub springs,
- the hydraulic clutch thrust bearing (if equipped),
- the magnet.

II - REFITTING OPERATION FOR THE MECHANISM 121188

COVER

121111
a Fit the "ball-spring" detents of the first-second (9)
and « third-fourth » (10) gear shafts.
a Keep them in their housing using the tool (Bvi. 1570)
(11) .

114745
a Check that the centring dowels are in place (7) .

a Refit the new magnet (8) .

WARNING
Applying excess sealant could cause it to be
squeezed out when parts are tightened. A mix-
ture of sealant and fluid may cause damage to
some components.

21A-24
 MANUAL GEARBOX
Mechanism cover: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

121187
a Ensure the correct fitting of:
- the fifth gear assembly lubrication channel (12) ,
- the breather pipe (13) .
114743
a Insert the "ball - spring" detent (15) of the fifth gear
shaft and compress it as soon as the fifth gear shaft
appears.
a Finish by fitting the mechanism housing.
a Refit the mechanism housing bolts.
a Torque tighten the mechanism housing bolts (25
N.m).

114309
a Refit the mechanism housing, while guiding the shift
finger (14) into the fork of the third gear.

21A-25
 MANUAL GEARBOX
Mechanism cover: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
Checking the fifth gear kickdown point

140937

121186

140938
a Measure the distance (X1) with fourth gear engaged
and the selector lever (18) against the « first-
second » gear claw (19) .
a Thickness washer:
121188
- dimension X1 from 21.70 to 22.02 mm = 0.66 mm
a Lift the reverse gear shaft (16) by inserting a hook washer,
through the housing opening.
- dimension X1 from 22.02 to 22.35 mm = 0.33 mm
a Fit the reverse gear locking "ball - spring" detent and washer,
the retaining stop (17) .
- dimension X1 greater than 22.35 mm = no washer.
a According to the dimension (X1) obtained, insert a
thickness washer between the mechanism housing
and the fifth gear kickdown point.
a Refit the fifth gear kickdown with the thickness
washer.
a Torque tighten the fifth gear kickdown point (20
N.m).

21A-26
 MANUAL GEARBOX
Mechanism cover: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
III - FINAL OPERATION
a Refit:
- the fifth gear synchroniser and pinions (see 21A,
Manual gearbox, 5th gear sprockets and syn-
chronisers: Removal - Refitting, page 21A-63) ,
- the fifth gear housing (see 21A, Manual gearbox,
5th gear housing: Removal - Refitting, page
21A-62) .
a Remove the gearbox from the component support
(see 2 1 A , Manual gearbox, Gearbox support
equipment: Use, page 21A-21) .
a Refit the gearbox (see Manual gearbox: Removal -
Refitting) .

21A-27
 MANUAL GEARBOX
Pressure plate housing bearing: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

Essential special tooling

X06 – X35, and JB1 or JB3 – X40 – X42 – X44 –
Bvi. 1576 Pressure plate housing bea- X48 – X53 – X56 – X57 – X64, and JB1 or JB3 –
ring refitting mandrel. X65, and JB1 or JB3 – X76, and JB1 or JB3
a
REMOVAL
Note:
The operation described is identical for both bea-
I - REMOVAL PREPARATION OPERATION.
rings.
a

IMPORTANT

To avoid all risk of damage to the systems, apply

the safety and cleanliness instructions and ope-
ration recommendations before carrying out any
repair:
- (see 21A, Manual gearbox, Manual gearbox:
Precautions for repair, page 21A-1) ,
- (see Vehicle: Precautions for repair) (01D,
Mechanical introduction).

a Remove the gearbox (see Manual gearbox: Remo-

val - Refitting) .
a Position the gearbox on the component support (see
21A, Manual gearbox, Gearbox support equip-
ment: Use, page 21A-21) .
a Remove:
- the fifth gear housing (see 21A, Manual gearbox, 114288
5th gear housing: Removal - Refitting, page
21A-62) , a Remove the circlips using circlip pliers.

- the fifth gear synchroniser and pinions (see 21A, a Remove the bearing from inside the housing using
Manual gearbox, 5th gear sprockets and syn- the tool (1) (Bvi. 1576) and the press.
chronisers: Removal - Refitting, page 21A-63) ,
- the mechanism housing (see 21A, Manual gear-
box, Mechanism cover: Removal - Refitting,
page 21A-22) .
X35, and JC5 – X64, and JC5 – X65, and JC5 –
X66 – X76, and JC5
II - OPERATION FOR THE REMOVAL OF THE
MECHANISM HOUSING BEARINGS
1 - Input shaft bearing
a
a Remove the circlips using circlip pliers.
Note: a Remove the input shaft bearing from inside the hou-
A press should be used to remove and refit the sing using the tool (Bvi. 1576) and the press.
bearings.
2 - Output shaft bearing
a Remove the output shaft bearing cage from inside
the housing, using the tool (Bvi. 1576) and the
press.

21A-28
 MANUAL GEARBOX
Pressure plate housing bearing: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

REFITTING
X35, and JC5 – X64, and JC5 – X65, and JC5 –
I - REFITTING PREPARATION OPERATION X66 – X76, and JC5

a Use SURFACE CLEANER (see Vehicle: Parts

1 - Input shaft bearing
and ingredients for the repairwork) to clean:
a Place:
- the bearing mating faces in the mechanism hou-
sing. - the new circlip in its housing,
- the bearing in the tool (Bvi. 1576).
- the mechanism housing.
a Knock the tool with the bearing using the press. The
a Parts always to be replaced: shape of the tool enables the circlip to be opened in
the housing and the bearing to be inserted.
- the removed bearings,
a Check that the circlip has been positioned correctly
- the lip seals, in the bearing channel.
- the O-rings,
2 - Output shaft bearing
- the clutch thrust bearing guide,

- the roll pins,

- input and output shaft bearing circlips,

- the mechanism housing bearing circlips,

- the hydraulic clutch slave cylinder (if fitted),

- the magnet.

II - OPERATION FOR THE REFITTING OF THE

MECHANISM HOUSING BEARINGS

X06 – X35, and JB1 or JB3 – X40 – X42 – X44 –

X48 – X53 – X56 – X57 – X64, and JB1 or JB3 –
X65, and JB1 or JB3 – X76, and JB1 or JB3

Note:
140933
The operation described is identical for both bea- a Fit the bearing cage in the tool (Bvi. 1576).
rings.
a Press on the tool with the bearing cage using the
a Place: press until it reaches the end stop.

- the new circlip in its housing,

- the bearing in the tool (Bvi. 1576).

a Knock the tool with the bearing using the press. The
shape of the tool enables the circlip to be opened in
the housing and the bearing to be inserted.

a Check that the circlip has been positioned correctly

in the bearing channel.

21A-29
 MANUAL GEARBOX
Pressure plate housing bearing: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
III - FINAL OPERATION
a Refit:
- the mechanism housing (see 21A, Manual gear-
box, Mechanism cover: Removal - Refitting,
page 21A-22) ,
- the fifth gear synchroniser and pinions (see 21A,
Manual gearbox, 5th gear sprockets and syn-
chronisers: Removal - Refitting, page 21A-63) ,
- the fifth gear housing (see 21A, Manual gearbox,
5th gear housing: Removal - Refitting, page
21A-62) .
a Remove the gearbox from the component support
(see 2 1 A , Manual gearbox, Gearbox support
equipment: Use, page 21A-21) .
a Refit the gearbox (see Manual gearbox: Removal -
Refitting) .

21A-30
 MANUAL GEARBOX
Gearbox shaft: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
II - REMOVAL OPERATION FOR THE GEARBOX
SHAFTS
IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 21A, Manual gearbox, Manual gear-
box: Precautions for repair, page 21A-1) .

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Remove the gearbox (see Manual gearbox: Remo-
val - Refitting)
a Position the gearbox on the component support (see
21A, Manual gearbox, Gearbox support equip-
ment: Use, page 21A-21)
a Remove the fifth gear housing (see 21A, Manual
gearbox, 5th gear housing: Removal - Refitting,
page 21A-62)
121106
a Remove the fifth gear pinion (see 21A, Manual
a Remove the fourth idle gear and the synchroniser
gearbox, 5th gear sprockets and synchronisers:
ring (1) .
Removal - Refitting, page 21A-63)
a Remove the fifth gear shaft (2) .
a Remove the mechanism housing (see 21A, Manual
gearbox, Mechanism cover: Removal - Refitting,
page 21A-22)

121107
a Lift the input shaft and secondary shaft slightly.
a Remove the reverse gear shaft (3) .

21A-31
 MANUAL GEARBOX
Gearbox shaft: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

121108 121109
a Simultaneously remove the first - second gear "se-
condary shaft - shaft-fork" assembly (7) .

101136
a Remove the third - fourth gear selector rod and shaft
- fork assembly (4) .
a Recover the three springs and the three synchroni-
ser rollers (6) .
a Remove the input shaft (5) .

21A-32
 MANUAL GEARBOX
Gearbox shaft: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
- the mechanism housings
a Parts always to be replaced:
- the lip seals,
- the O-rings,
- the clutch thrust bearing guide
- the gear lock rings,
- the roll pins,
- the input and output shaft bearing circlips,
- the selector rod hub springs,
- the hydraulic clutch slave cylinder (if fitted).
- the magnet.

II - REFITTING OPERATION FOR THE GEARBOX

SHAFTS

121110

121110
a Place the three safety stops (10) in the housing.
121112
a Do not forget to recover the three safety stops (8)
and the internal stop in the first - second gear shaft
(9) .

REFITTING

I - REFITTING PREPARATION OPERATION

a Use SURFACE CLEANER (see Vehicle: Parts
and ingredients for the repairwork) to clean:
- the shafts,
- the shaft mating surfaces.

21A-33
 MANUAL GEARBOX
Gearbox shaft: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

121109 121108

121112 101136
a Simultaneously fit the secondary shaft (11) and the a Simultaneously fit the "third-fourth selector rod and
first-second gear shaft-fork (12) . shaft-fork (14) and input shaft" (15) assembly.
a Do not forget to fit the safety stop (13) in the first-se- a Shift into third gear and insert the three springs and
cond gear fork shaft. three synchroniser rollers (16) .
a Disengage third gear.

21A-34
 MANUAL GEARBOX
Gearbox shaft: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
III - FINAL OPERATION
a Refit the mechanism housing (see 21A, Manual
gearbox, Mechanism cover: Removal - Refitting,
page 21A-22)
a Refit the fifth gear pinion (see 21A, Manual gear-
box, 5th gear sprockets and synchronisers: Re-
moval - Refitting, page 21A-63)
a Refit the fifth gear housing (see 21A, Manual gear-
box, 5th gear housing: Removal - Refitting, page
21A-62)
a Remove the gearbox from the component support
(see 2 1 A , Manual gearbox, Gearbox support
equipment: Use, page 21A-21)
a Refit the gearbox (see Manual gearbox: Removal -
Refitting)

121107
a Lift the input shaft and secondary shaft slightly.
a Position the reverse gear shaft (17) .

121106
a Fit the fourth idle gear with its synchroniser ring (18)
.
a Fit the support washer (19) on the secondary shaft.

21A-35
 MANUAL GEARBOX
Output shaft: Stripping - Rebuilding 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
II - OPERATION FOR STRIPPING THE OUTPUT
SHAFT
IMPORTANT
To avoid all risk of damage to the systems, apply
X06 – X35, and JB1 or JB3 – X40 – X42 – X44 –
the safety and cleanliness instructions and opera- X48 – X53 – X56 – X57 – X64, and JB1 or JB3 –
tion recommendations before carrying out any
X65, and JB1 or JB3 – X76, and JB1 or JB3
repair (see 21A, Manual gearbox, Manual gear-
box: Precautions for repair, page 21A-1) .

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Remove the gearbox (see Manual gearbox: Remo-
val - Refitting) .
a Position the gearbox on the component support (see
21A, Manual gearbox, Gearbox support equip-
ment: Use, page 21A-21) .
a Remove:
- the fifth gear housing (see 21A, Manual gearbox,
5th gear housing: Removal - Refitting, page
21A-62) ,
- the fifth gear synchroniser and pinions (see 21A,
Manual gearbox, 5th gear sprockets and syn-
chronisers: Removal - Refitting, page 21A-63) ,
114310
- the mechanism housing (see 21A, Manual gear- a Mount the output shaft in a vice fitted with jaws.
box, Mechanism cover: Removal - Refitting,
page 21A-22) , a Remove:

- the gearbox shafts (see 21A, Manual gearbox, - the bearing,

Gearbox shaft: Removal - Refitting, page 21A- - the setting washer,
31) .
- the fourth gear pinion (1) ,
- the third/fourth gear synchroniser hub (2) .

21A-36
 MANUAL GEARBOX
Output shaft: Stripping - Rebuilding 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

114315 114313
a Remove: a Remove:
- the lock ring (3) using circlip pliers and tweezers, - the lock ring (7) using circlip pliers and tweezers,
- the splined washer (4) . - the splined washer (8) .

114314 114312
a Remove: a Remove:
- the third gear pinion (5) , - the second gear pinion (9) ,
- the splined washer (6) . - the splined washer (10) .

21A-37
 MANUAL GEARBOX
Output shaft: Stripping - Rebuilding 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

114311 140929
a Remove: a Remove the « ring - hub - third gear pinion » assem-
bly using a press and an extractor (14) , lifting it from
- the lock ring (11) using circlip pliers and tweezers,
underneath the claw teeth of the third gear pinion.
- the first - second gear synchroniser hub (12) ,
- the first gear pinion (13) .

X35, and JC5 – X64, and JC5 – X65, and JC5 –

X66 – X76, and JC5
a

Note:
The rings supporting the second, third and fourth
gears are fitted tightened on the shafts. These
must always be replaced during refitting.

a Remove:
- the bearing,
- the setting washer,
- the fourth gear pinion, 140930

- the third/fourth gear synchroniser hub. a Remove the « rings - second gear pinion - first gear
pinion - hub - selector rod » assembly using a press
and an extractor, lifting from underneath the first pi-
nion.

21A-38
 MANUAL GEARBOX
Output shaft: Stripping - Rebuilding 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
- the clutch thrust bearing guide,
- the roll pins,
- the input and output shaft bearing circlips,
- the selector rod hub springs,
- the hydraulic clutch thrust bearing (if fitted),
- the magnet.
a Check all the parts (see 21A, Manual gearbox, Ma-
nual gearbox: Check, page 21A-18) .

II - OPERATION FOR REBUILDING THE OUTPUT

SHAFT

X06 – X35, and JB1 or JB3 – X40 – X42 – X44 –

X48 – X53 – X56 – X57 – X64, and JB1 or JB3 –
X65, and JB1 or JB3 – X76, and JB1 or JB3
a Mount the output shaft in a vice fitted with jaws.
140931
a Remove the bearing ring (15) from its support on the
output shaft sprocket teeth using a press and an ex-
tractor, taking care not to damage them.

REFITTING

I - REBUILDING PREPARATION OPERATION

a Clean all the removed parts using SURFACE
CLEANER (see Vehicle: Parts and ingredients
for the repairwork) .

X35, and JC5 – X64, and JC5 – X65, and JC5 –

X66 – X76, and JC5
a Always replace the gear lock rings.
100410
a Oil the synchroniser rings.

Note:
X06 – X35, and JB1 or JB3 – X40 – X42 – X44 –
X48 – X53 – X56 – X57 – X64, and JB1 or JB3 – Make sure that the notches on the double cone
X65, and JB1 or JB3 – X76, and JB1 or JB3 synchroniser are correctly positioned.

a Always replace the gear supporting rings.

a Parts always to be replaced:

- the lip seals,
- the O-rings,

21A-39
 MANUAL GEARBOX
Output shaft: Stripping - Rebuilding 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

114311 114313
a Refit: a Refit:
- the first gear pinion (16) , - the splined washer (21) ,
- the first - second gear synchroniser hub (17) , - the lock ring (22) using circlip pliers and tweezers.
- the lock ring (18) using circlip pliers and tweezers.

114314

114312 a Refit:
a Refit: - the splined washer (23) ,
- the splined washer (19) , - the third gear pinion (24) .
- the second gear pinion (20) .

21A-40
 MANUAL GEARBOX
Output shaft: Stripping - Rebuilding 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
- the bearing.

X35, and JC5 – X64, and JC5 – X65, and JC5 –

X66 – X76, and JC5
a Refit the bearing ring using the used bearing cone
for support with a press.

Note:
It is necessary to use a heater plate set at 150˚C
for refitting the rings.

114315
a Refit:
- the splined washer (25) ,
- the lock ring (26) using circlip pliers and tweezers.

140934
a Place the new rings on the cold heater plate.
a Heat the rings for 15 minutes, with the thermostat
set to 150˚C.

114310
a Refit:
- the third - fourth gear synchroniser hub (27) ,
- the fourth gear pinion (28) ,
- the setting washer,

21A-41
 MANUAL GEARBOX
Output shaft: Stripping - Rebuilding 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

140939

a Refit the springs (29) in a « heart-shaped

configuration » , observing the direction of fitting of
the flat part on the synchroniser hub end.
a Take a third ring from the heater plate and fit it on the
140935 shaft using pliers.
a Position the first gear pinion on the output shaft.
a Correctly place the ring against the hub using a
a Fit the selector rod for first - second gear on the hub press and a tube with a 33 mm inner diameter.
and refit the synchroniser springs.
a Align and engage the notches on the synchroniser
a Align and engage the notches on the synchroniser ring with those on the hub.
ring with those on the hub.
a Refit the fourth gear pinion on the shaft.
a Refit the first - second gear synchroniser hub.
a Adjust the input shaft (see 21A, Manual gearbox,
a Remove a ring from the heater plate and fit it on the Gearbox shaft: Adjustment, page 21A-44) .
shaft using pliers.
a Refit:
a Correctly place the ring against the hub using a
press and a tube with a 33 mm inner diameter. - the setting washer,
a Refit the second gear pinion and the washer on the - the bearing.
output shaft.
a Remove a second ring from the heater plate and fit it
on the shaft using pliers.
a Correctly place the ring against the washer using a
press and a tube with a 33 mm inner diameter. III - FINAL OPERATION

a Refit the third gear pinion on the shaft. a Refit:

a Fit the third - fourth gear selector rod on the hub. - the mechanism housing (see 21A, Manual gear-
box, Mechanism cover: Removal - Refitting,
a Align and engage the notches on the synchroniser page 21A-22) ,
ring with those on the hub.
- the fifth gear synchroniser and pinions (see 21A,
a Refit the third - fourth gear synchroniser hub.
Manual gearbox, 5th gear sprockets and syn-
chronisers: Removal - Refitting, page 21A-63) ,
- the fifth gear housing (see 21A, Manual gearbox,
5th gear housing: Removal - Refitting, page
21A-62) .
a Remove the gearbox from the component support
(see 2 1 A , Manual gearbox, Gearbox support
equipment: Use, page 21A-21) .

21A-42
 MANUAL GEARBOX
Output shaft: Stripping - Rebuilding 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
a Refit the gearbox (see Manual gearbox: Removal -
Refitting) .

21A-43
 MANUAL GEARBOX
Gearbox shaft: Adjustment 21A
X35, and JC5 – X64, and JC5 – X65, and JC5 – X66 – X76, and JC5
a Fit:
Essential special tooling
- the input shaft,
Bvi. 1161 Steel plate to attach DTI
- the mechanism housing.
gauge and 0.6 and 1.6 stan-
dard wrench. a Torque tighten the mechanism housing bolts (see
21A, Manual gearbox, Mechanism cover: Remo-
Essential equipment val - Refitting, page 21A-22) .

dial gauge support

IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 21A, Manual gearbox, Manual gear-
box: Precautions for repair, page 21A-1) .

I - ADJUSTMENT PREPARATION OPERATION

a Remove the gearbox (see Manual gearbox: Remo-
val - Refitting) .
a Position the gearbox on the component support (see
21A, Manual gearbox, Gearbox support equip-
ment: Use, page 21A-21) .
a Remove:
114728
- the mechanism housing (see 21A, Manual gear- a Fit:
box, Mechanism cover: Removal - Refitting,
page 21A-22) , - the presetting washer (0.6 mm) (1) of tool (Bvi.
1161),
- the gearbox shafts (see 21A, Manual gearbox,
Gearbox shaft: Removal - Refitting, page 21A- - the lock washer (2) ,
31) , - the gear supporting ring (3) ,
- the differential (see 21A, Manual gearbox, Ma- - the fully tightened nut (4) .
nual gearbox differential: Removal - Refitting,
page 21A-54) .
a Clean (see 21A, Manual gearbox, Manual gear-
box: Precautions for repair, page 21A-1) :

- the shafts,
- the shaft mating surfaces,

- the joint face of the mechanism housing and the

clutch housing.

II - ADJUSTING PLAY IN THE INPUT SHAFT

BEARINGS

Note:
The adjustment must be performed without the
differential and without the output shaft.

21A-44
 MANUAL GEARBOX
Gearbox shaft: Adjustment 21A
X35, and JC5 – X64, and JC5 – X65, and JC5 – X66 – X76, and JC5

141099 141245
a Fit: a Rotate the input shaft several times to fit the bea-
rings.
- the support plate (Bvi. 1161) (5) on the tripod bowl
mountings, a Calibrate the dial gauge to zero.
- the dial gauge support (6) on the support plate. a Pull the input shaft upwards using two screwdrivers
- the dial gauge (7) on the dial gauge support. as levers (8) .
a Take a reading from the dial gauge.
a Repeat the abovementioned operations several ti-
mes.
a Calculate the average of the readings.
a Determine the thickness of the adjustment washer
using the following procedure:
Thickness of the adjustment washer (mm) = value of
the presetting washer (mm) + average of the dial
gauge readings - 0.02 mm (value to subtract to gua-
rantee minimum play).
Example:
Value of the presetting washer = 0.62 mm.
Average of the dial gauge readings = 0.50 mm.
Adjustment washer = 0.62 + 0.50 - 0.02 = 1.10
mm.
Given that washers vary in thickness from 0.86 mm
to 1.30 mm in 0.04 mm increments, choose the
1.10 mm thick washer from the set.
a Remove:
- the mechanism housing bolts,
- the mechanism housing,
- the input shaft.

21A-45
 MANUAL GEARBOX
Gearbox shaft: Adjustment 21A
X35, and JC5 – X64, and JC5 – X65, and JC5 – X66 – X76, and JC5
III - ADJUSTING PLAY IN THE OUTPUT SHAFT
BEARINGS

Note:
The adjustment must be performed without the
differential and without the input shaft.

a Fit:

- the output shaft,

- the mechanism housing.

a Torque tighten the mechanism housing bolts (see

21A, Manual gearbox, Mechanism cover: Remo-
val - Refitting, page 21A-22) .

114325
a Rotate the output shaft several times to fit the bea-
rings.
a Calibrate the dial gauge to zero.
a Pull the output shaft upwards using two screwdrivers
as levers (12) .
a Take a reading from the dial gauge.
a Repeat the abovementioned operations several ti-
mes.
a Calculate the average of the readings.
a Determine the thickness of the adjustment washer
using the following procedure:
Thickness of the adjustment washer (mm) = prescri-
bed value (mm) + presetting washer value + avera-
ge of the dial gauge readings.
114316
Example:
a Fit:
Prescribed value = 0.26 mm.
- the presetting washer (9) (1.6 mm) of tool (Bvi. Value of the presetting washer = 1.60 mm.
1161),
Average of the dial gauge readings = 0.49 mm.
- the bush (10) , Adjustment washer = 0.26 + 1.60 + 0.49 = 2.35
mm.
- the fully tightened ring bolt (11) .
Given that washers vary in thickness from 2.15 mm
a Fit: to 2.43 mm in 0.04 mm increments, choose the
2.35 mm thick washer from the set.
- the support plate (Bvi. 1161) on the spider bowl a Remove:
mounting,
- the mechanism housing bolts,
- the dial gauge support on the support plate, - the mechanism housing,
- the dial gauge on the dial gauge support. - the output shaft.

21A-46
 MANUAL GEARBOX
Gearbox shaft: Adjustment 21A
X35, and JC5 – X64, and JC5 – X65, and JC5 – X66 – X76, and JC5
IV - FINAL OPERATION
a Refit:
- the differential (see 21A, Manual gearbox, Ma-
nual gearbox differential: Removal - Refitting,
page 21A-54) ,
- the gearbox shafts (see 21A, Manual gearbox,
Gearbox shaft: Removal - Refitting, page 21A-
31) ,
- the mechanism housing (see 21A, Manual gear-
box, Mechanism cover: Removal - Refitting,
page 21A-22) .
a Remove the gearbox from the component support
(see 2 1 A , Manual gearbox, Gearbox support
equipment: Use, page 21A-21) .
a Refit the gearbox (see Manual gearbox: Removal -
Refitting) .

21A-47
 MANUAL GEARBOX
Clutch housing bearing: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
II - REMOVAL OPERATION FOR THE CLUTCH
Essential special tooling HOUSING BEARINGS
Bvi. 1165 For extracting output shaft a
bearing on clutch/differential
housing. Note:
A press should be used to remove the clutch
thrust bearing guide.
REMOVAL

I - REMOVAL PREPARATION OPERATION 1 - Output shaft bearing

a
X06 – X35, and JB1 or JB3 – X40 – X42 – X44 –
IMPORTANT X48 – X53 – X56 – X57 – X64, and JB1 or JB3 –
X65, and JB1 or JB3 – X76, and JB1 or JB3
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and ope- a
ration recommendations before carrying out any
repair:
- (see 21A, Manual gearbox, Manual gearbox:
Precautions for repair, page 21A-1) ,
- (see Vehicle: Precautions for repair) (01D,
Mechanical introduction).

a Remove the gearbox (see Manual gearbox: Remo-

val - Refitting) .
a Position the gearbox on the component support (see
21A, Manual gearbox, Gearbox support equip-
ment: Use, page 21A-21) .
a Remove:
- the fifth gear housing (see 21A, Manual gearbox,
5th gear housing: Removal - Refitting, page
21A-62) ,
- the fifth gear synchroniser and pinions (see 21A,
Manual gearbox, 5th gear sprockets and syn-
chronisers: Removal - Refitting, page 21A-63) , 101137

- the mechanism housing (see 21A, Manual gear- a Cut the base of the plastic lubrication tube located at
box, Mechanism cover: Removal - Refitting, the centre of the bearing in order to facilitate access
page 21A-22) , for the slide hammer puller (1) .

- the gearbox shafts (see 21A, Manual gearbox, a Fit the 42 mm slide hammer puller.
Gearbox shaft: Removal - Refitting, page 21A- a Remove the output shaft bearing from the clutch
31) , housing.
- the differential (see 21A, Manual gearbox, Ma-
nual gearbox differential: Removal - Refitting,
page 21A-54) .

21A-48
 MANUAL GEARBOX
Clutch housing bearing: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
- the plastic lubrication tube,

X35, and JC5 – X64, and JC5 – X65, and JC5 – - the hydraulic clutch slave cylinder (if fitted),
X66 – X76, and JC5
- the magnet.

II - OPERATION FOR REFITTING THE CLUTCH

HOUSING BEARINGS

1 - Output shaft bearing

a Position a new deflector.

X06 – X35, and JB1 or JB3 – X40 – X42 – X44 –

X48 – X53 – X56 – X57 – X64, and JB1 or JB3 –
X65, and JB1 or JB3 – X76, and JB1 or JB3
a Using a press, refit the output shaft bearing until it is
flush with the internal surface of the clutch housing
using a tube with a 49 mm outer diameter.

140932
X35, and JC5 – X64, and JC5 – X65, and JC5 –
a Cut the base of the plastic lubrication tube located at X66 – X76, and JC5
the centre of the bearing in order to facilitate access
for the slide hammer puller (Bvi. 1165) (2) . a Using a press, refit the output shaft bearing until it is
flush with the internal surface of the clutch housing
a Position the (Bvi. 1165). using a tube with a 58 mm outer diameter.
a Remove the output shaft bearing from the clutch
housing.

2 - Input shaft bearing

a Remove the input shaft bearing (see Input shaft lip
seal: Removal - Refitting) .

I - REFITTING PREPARATION OPERATION

a Use SURFACE CLEANER (see Vehicle: Parts
and ingredients for the repairwork) to clean:
- the bearing mating faces in the clutch housing.
- the clutch housing.
a Parts always to be replaced:
- the removed bearings,
- the lip seals,
- the O-rings,
114301
- the clutch thrust bearing guide,
a Crimp the output shaft bearing on the clutch housing
- the roll pins, using a chisel.

21A-49
 MANUAL GEARBOX
Clutch housing bearing: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
2 - Input shaft bearing
a Refit the input shaft bearing (see Input shaft lip
seal: Removal - Refitting) .

III - FINAL OPERATION

a Refit:
- the differential (see 21A, Manual gearbox, Ma-
nual gearbox differential: Removal - Refitting,
page 21A-54) ,
- the gearbox shafts (see 21A, Manual gearbox,
Gearbox shaft: Removal - Refitting, page 21A-
31) ,
- the mechanism housing (see 21A, Manual gear-
box, Mechanism cover: Removal - Refitting,
page 21A-22) ,
- the fifth gear synchroniser and pinions (see 21A,
Manual gearbox, 5th gear sprockets and syn-
chronisers: Removal - Refitting, page 21A-63) ,
- the fifth gear housing (see 21A, Manual gearbox,
5th gear housing: Removal - Refitting, page
21A-62) .
a Remove the gearbox from the component support
(see 2 1 A , Manual gearbox, Gearbox support
equipment: Use, page 21A-21) .
a Refit the gearbox (see Manual gearbox: Removal -
Refitting) .

21A-50
 MANUAL GEARBOX
Manual gearbox selector shaft: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
II - REMOVAL OPERATION FOR THE MANUAL
Essential special tooling GEAR BOX SELECTOR SHAFT
Bvi. 1162 Selector shaft bearing repla-
cement tool.

IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 21A, Manual gearbox, Manual gear-
box: Precautions for repair, page 21A-1) .

REMOVAL

I - REMOVAL PREPARATION OPERATION.

a Remove the gearbox (see Manual gearbox: Remo-
val - Refitting) .
a Position the gearbox on the component support (see
21A, Manual gearbox, Gearbox support equip- 114305
ment: Use, page 21A-21) .
a Remove the pin (1) from the selector finger.
a Remove:
- the fifth gear housing (see 21A, Manual gearbox,
5th gear housing: Removal - Refitting, page
21A-62) ,
- the fifth gear synchroniser and pinions (see 21A,
Manual gearbox, 5th gear sprockets and syn-
chronisers: Removal - Refitting, page 21A-63) ,
- the mechanism housing (see 21A, Manual gear-
box, Mechanism cover: Removal - Refitting,
page 21A-22) .

121183

a Remove:

- the locking ring (2) ,

- the ball joint bearing shell (3) ,

- the selector shaft (4) ,

- the seal (5) ,

- the gaiter (6) .

21A-51
 MANUAL GEARBOX
Manual gearbox selector shaft: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
II - OPERATION FOR REFITTING THE MANUAL
GEAR BOX SELECTOR SHAFT

121184
a Remove both rings (7) from the manual gearbox se-
lector shaft using a 16.5 mm diameter tube and a
small hammer.

REFITTING

93231
I - REFITTING PREPARATION OPERATION
a Refit the manual gearbox selector shaft rings using
a Use SURFACE CLEANER (see Vehicle: Parts the tool (Bvi. 1162) (8) and a used selector shaft (9)
and ingredients for the repairwork) to clean: .
- the mating faces of the two rings on the manual
gearbox selector shaft in the mechanism housing,
- the seal mating face,
- the mechanism housing.
a Parts always to be replaced:
- the removed bearings,
- the manual gearbox selector shaft rings,
- the lip seals,
- the O-rings,
- the clutch thrust bearing guide,
- the roll pins,
- the input and output shaft bearing circlips,
- the hydraulic clutch thrust bearing (if fitted),
- the magnet.

141244
a Fit the selector shaft seal, leaving a 2.5 mm space
(X1) between the selector shaft seal and the mecha-
nism housing.

21A-52
 MANUAL GEARBOX
Manual gearbox selector shaft: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
a - the lock ring (12) .

Note:
Failure to leave a 2.5 mm space between the Reverse gear brake
selector shaft seal and the mechanism housing
will make it impossible to refit the gaiter.

141205

a The fifth gear shaft is fitted with a ratchet (13) that

lowers the shaft slightly when the selector lever se-
lects reverse gear (14) , in order to activate synchro-
nisation without using the fifth gear claw
mechanism.

Therefore the input axle assembly slows and ena-

114305 bles reverse gear to be selected.

a Fit the selector shaft while simultaneously inserting a To test this, shift into reverse gear before refitting the
the selector lever.
fifth gear housing: the fifth gear shaft must lower and
a Refit the pin (10) for the selector lever. raise slightly before reverse gear is engaged.

III - FINAL OPERATION

a Refit:

- the mechanism housing (see 21A, Manual gear-

box, Mechanism cover: Removal - Refitting,
page 21A-22) ,

- the fifth gear synchroniser and pinions (see 21A,

Manual gearbox, 5th gear sprockets and syn-
chronisers: Removal - Refitting, page 21A-63) ,

- the fifth gear housing (see 21A, Manual gearbox,

5th gear housing: Removal - Refitting, page
21A-62) .

a Remove the gearbox from the component support

(see 2 1 A , Manual gearbox, Gearbox support
121183 equipment: Use, page 21A-21) .
a Refit:
a Refit the gearbox (see Manual gearbox: Removal -
- the ball joint bearing shell (11) , Refitting) .

21A-53
 MANUAL GEARBOX
Manual gearbox differential: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
II - REMOVAL OPERATION FOR THE
Essential special tooling DIFFERENTIAL
Bvi. 1057 Differential locking tool
X06 – X35, and JB1 or JB3 – X40 – X42 – X44 –
Bvi. 946 Mandrel for fitting locking X48 – X53 – X56 – X57 – X64, and JB1 or JB3 –
spring ring on sunwheel. X65, and JB1 or JB3 – X76, and JB1 or JB3

Tightening torquesm

differential nut (initial 11 N.m

torque)

differential nut 130 N.m

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

IMPORTANT

To avoid all risk of damage to the systems, apply

the safety and cleanliness instructions and ope-
ration recommendations before carrying out any
repair: 114747
- (see 21A, Manual gearbox, Manual gearbox: a
Precautions for repair, page 21A-1) ,
Note:
- (see Vehicle: Precautions for repair) (01D,
Mechanical introduction). A press should be used in order to release the
strain between the ring and the housing.
a Remove the gearbox (see Manual gearbox: Remo-
val - Refitting) . Fit:

a Position the gearbox on the component support (see - a rubber or wooden block on the press plate,
21A, Manual gearbox, Gearbox support equip- - the crownwheel side of the differential on the rub-
ment: Use, page 21A-21) . ber or wooden block.
a Remove: a Take a cylinder suitable for the outer diameter of the
- the fifth gear housing (see 21A, Manual gearbox, differential output housing and push the housing
5th gear housing: Removal - Refitting, page using the press at (1) to release any strain in the lock
21A-62) , ring.
a Remove the lock ring (2) using circlip pliers.
- the fifth gear synchroniser and pinions (see 21A,
Manual gearbox, 5th gear sprockets and syn- a Remove the differential by pushing on the sunwheel
chronisers: Removal - Refitting, page 21A-63) , (3) .
- the mechanism housing (see 21A, Manual gear-
box, Mechanism cover: Removal - Refitting,
page 21A-22) ,
- the gearbox shafts (see 21A, Manual gearbox,
Gearbox shaft: Removal - Refitting, page 21A-
31) ,
- the differential output seal (see Differential output
seal: Removal - Refitting) .

21A-54
 MANUAL GEARBOX
Manual gearbox differential: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
III - TACHOMETER REMOVAL OPERATION

X35, and JC5 – X64, and JC5 – X65, and JC5 –

X66 – X76, and JC5 1 - Mechanical tachometer
a Remove:
- the tachometer crownwheel,
- he hollow sunwheel (see Hollow sunwheel: Re-
moval - Refitting) .
a Turn the differential by hand so that the tachometer
sprocket can be accessed.

114761

a Secure the differential unit - crownwheel assembly

141243
using the tool (Bvi. 1057) mounted on the housing.
a Unclip the shaft by pulling it upward using long-
nosed pliers.
a Remove the sprocket from its housing using the
pliers.

141128

a Remove the differential nut.

a Recover the bearing pretensioning torque perma-
nent shim.
a Remove the differential by pushing on the sunwheel.

21A-55
 MANUAL GEARBOX
Manual gearbox differential: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
2 - Electronic tachometer - the hydraulic clutch slave cylinder (if fitted),
- the magnet.

II - TACHOMETER REFITTING OPERATION

1 - Mechanical tachometer
a Refit:
- the new tachometer sprocket using flat-nosed
pliers,
- the tachometer sprocket shaft.

141313

a Move the tabs of the spring (5) using a screwdriver.

a Remove:
- the spring (5) ,
- the tachometer target (4) . 141242
a Correctly position the shaft in relation to the sprocket
REFITTING collet pins.
a Ensure that it has been clipped correctly by tapping
I - REFITTING PREPARATION OPERATION the shaft with a mallet.

a Use SURFACE CLEANER (see Vehicle: Parts a Check the rotation of the tachometer shaft.
and ingredients for the repairwork) to clean: a Refit the hollow sunwheel (see Hollow sunwheel:
- the shafts, Removal - Refitting) .

- the shaft mating surfaces,

2 - Electronic tachometer
- the mechanism housings.
a Fit the tachometer target on the differential.
a Parts always to be replaced:
a Refit the tachometer target mounting spring using a
- the lip seals, tube with a 49 mm internal diameter.
- the O-rings, a Check the fitting of the spring tabs in the differential
neck.
- the clutch thrust bearing guide,
- the tachometer sprocket and sprocket shaft,
- the tachometer crownwheel,
- the tachometer target spring,
- the gear lock rings,
- the roll pins,
- the input and output shaft bearing circlips,
- the selector rod hub springs,

21A-56
 MANUAL GEARBOX
Manual gearbox differential: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
III - REFITTING OPERATION FOR THE - 2nd case : the bearings are reused, but one of the
DIFFERENTIAL parts is replaced (unit or housing). Use the thickest
adjustment washer in the set (2.525 mm). Check
and potentially adjust the pretensioning torque,
X06 – X35, and JB1 or JB3 – X40 – X42 – X44 –
X48 – X53 – X56 – X57 – X64, and JB1 or JB3 – - 3rd case : the bearings are new (with or without re-
X65, and JB1 or JB3 – X76, and JB1 or JB3 placement of the unit and housing). Use the thic-
kest adjustment washer in the set (2.525 mm).
Check and potentially adjust the pretensioning tor-
que.

a Refit the sunwheel stem end bearing on the differen-

tial unit.

a Fit the adjustment washer and the rubber nut, obser-

ving the direction of fitting (neck on bearing side).

a Torque tighten the differential nut (initial torque)

(11 N.m).

114756

Note:
A press should be used to refit the lock ring.

Refit:
- the crownwheel side of the differential on a rubber
or wooden block,

- the box casing on the differential.

a Position the lock ring on the cone of the tool (Bvi.
946).
a Fit the tool and its cone (Bvi. 946) on the differential
output shaft.
a Push the assembly using the press until the lock ring
is positioned. 141128

a Remove the tool (Bvi. 1057) and turn the differential

to fit the bearings.

a Refit the (Bvi. 1057).

X35, and JC5 – X64, and JC5 – X65, and JC5 –
X66 – X76, and JC5 a Torque tighten the differential nut (130 N.m).

a Remove the (Bvi. 1057).

Adjusting the bearing pretensioning torque

b - Verifying the pretensioning torque

a - Choosing the adjustment washer:
a Three possible cases can arise: a Rotate the differential several times.

- 1st case : all the parts are reused (bearings, diffe- a Wind a string around the crownwheel.
rential unit, housing). Refit the original adjustment
washer and check the pretensioning torque, a Pull on the string using a spring balance.

21A-57
 MANUAL GEARBOX
Manual gearbox differential: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
- the mechanism housing (see 21A, Manual gear-
box, Mechanism cover: Removal - Refitting,
page 21A-22) ,
- the fifth gear synchroniser and pinions (see 21A,
Manual gearbox, 5th gear sprockets and syn-
chronisers: Removal - Refitting, page 21A-63) ,
- the fifth gear housing (see 21A, Manual gearbox,
5th gear housing: Removal - Refitting, page
21A-62) .
a Remove the gearbox from the component support
(see 2 1 A , Manual gearbox, Gearbox support
equipment: Use, page 21A-21) .
a Refit the gearbox (see Manual gearbox: Removal -
Refitting) .

114763

a 1st and 2nd case - bearings reused:

- the differential must rotate under a load between 0

and 20 N.

a 3rd case - new bearings:

- the differential must rotate under a load between

16 and 32 N.

This is the load required to maintain the rotation of

the differential.

a If the adjustment is not correct:

- the pretensioning torque increases by approxima-

tely 7 to 8 N when the thickness of the adjustment
washer decreases 0.5 mm and vice versa.

There is a set of adjustment washers 2.225 mm to

2.525 mm thick in 0.05 increments.

a Fit with the new adjustment washer and re-check the

pretensioning torque.

IV - FINAL OPERATION

a Refit:

- the differential output seal (see Differential output

seal: Removal - Refitting) ,

- the gearbox shafts (see 21A, Manual gearbox,

Gearbox shaft: Removal - Refitting, page 21A-
31) ,

21A-58
 MANUAL GEARBOX
Manual gearbox differential bearing: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
Bearing on the crownwheel side:
Essential special tooling

Bvi. 1059 Differential bearing bushes fit-

ting kit

REMOVAL

I - REMOVAL PREPARATION OPERATION

a

Note:
Consult the safety and cleanliness advice and
operation recommendations before carrying out
any repair (see 21A, Manual gearbox, Manual
gearbox: Precautions for repair, page 21A-1)

a Remove the gearbox (see Manual gearbox: Remo-

val - Refitting)
a Position the gearbox on the component support (see 114751
21A, Manual gearbox, Gearbox support equip-
a Insert a small metallic bar (1) inside the casing and
ment: Use, page 21A-21)
place it flat on the bearing.
a Remove the fifth gear housing (see 21A, Manual
a Use the small bar as a support for the tube (2) .
gearbox, 5th gear housing: Removal - Refitting,
page 21A-62) a Remove the bearing (3) with the press towards the
housing exterior.
a Remove the fifth gear pinion (see 21A, Manual
gearbox, 5th gear sprockets and synchronisers:
Removal - Refitting, page 21A-63) Bearing on the sunwheel side:
a Remove the mechanism housing (see 21A, Manual
gearbox, Mechanism cover: Removal - Refitting,
page 21A-22)
a Remove the gearbox shafts (see 21A, Manual gear-
box, Gearbox shaft: Removal - Refitting, page
21A-31)
a Remove the differential (see 21A, Manual gearbox,
Manual gearbox differential: Removal - Refitting,
page 21A-54)

II - REMOVAL OPERATION FOR THE

DIFFERENTIAL BEARINGS
114752
a
a Remove the bearing's lock ring (4) .
Note:
a Place a 50mm diameter tube (6) on the bearing.
A press should be used to remove the bearings.
a Remove the bearing (5) with the press towards the
housing interior.

21A-59
 MANUAL GEARBOX
Manual gearbox differential bearing: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76

REFITTING Bearing on the sunwheel side:

I - REFITTING PREPARATION OPERATION

a Use SURFACE CLEANER (see Vehicle: Parts
and ingredients for the repairwork) to clean:
- the bearing mating faces in the mechanism hou-
sing.
- the mechanism housing.
a Parts always to be replaced:
- the removed bearings,

- the lip seals,

- the O-rings,
- the clutch thrust bearing guide,
- the roll pins,
- the input and output shaft bearing circlips,
114753
- the mechanism housing bearing circlips, a Refit the bearing (10) using a 65 mm diameter tube
(12) .
- the hydraulic clutch slave cylinder (if fitted),
- the magnet.
Note:

II - OPERATION FOR REFITTING THE The bearing's sealing race (11) must be facing
DIFFERENTIAL BEARINGS the side opposite the crownwheel.

Bearing on the crownwheel side: a Refit a new bearing lock ring (13) .

114757

a Refit the bearing using the press and the tool (7)
(Bvi. 1059), using the external bearing bush (9) as a
support.

Note:
The bearing's sealing race (8) must be facing the
side opposite the crownwheel.

21A-60
 MANUAL GEARBOX
Manual gearbox differential bearing: Removal - Refitting 21A
X06 – X35 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64 – X65 – X66 – X76
III - FINAL OPERATION
a Refit the differential (see 21A, Manual gearbox,
Manual gearbox differential: Removal - Refitting,
page 21A-54)
a Refit the gearbox shafts (see 21A, Manual gear-
box, Gearbox shaft: Removal - Refitting, page
21A-31)
a Refit the mechanism housing (see 21A, Manual
gearbox, Mechanism cover: Removal - Refitting,
page 21A-22)
a Refit the fifth gear pinion (see 21A, Manual gear-
box, 5th gear sprockets and synchronisers: Re-
moval - Refitting, page 21A-63)
a Refit the fifth gear housing (see 21A, Manual gear-
box, 5th gear housing: Removal - Refitting, page
21A-62)
a Remove the gearbox from the component support
(see 2 1 A , Manual gearbox, Gearbox support
equipment: Use, page 21A-21)
a Refit the gearbox (see Manual gearbox: Removal -
Refitting)

21A-61
 MANUAL GEARBOX
5th gear housing: Removal - Refitting 21A
X06 – X35, and JB1 or JB3 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64, and JB1 or JB3 – X65, and JB1 or
JB3 – X76, and JB1 or JB3

REFITTING
Tightening torquesm
I - REFITTING PREPARATION OPERATION
fifth gear housing moun- 25 N.m.
ting bolts a Clean the joint faces of the mechanism housing
using SUPER CLEANING AGENT FOR JOINT FA-
CES (see Vehicle: Parts and ingredients for the
REMOVAL repairwork) .

I - REMOVAL PREPARATION OPERATION.

WARNING
a
Do not scrape the joint faces of the aluminium,
Note: any damage caused to the joint face will result in
a risk of leaks.
Consult the safety and cleanliness advice and
operation recommendations before carrying out
a Remove the residue using a plastic spatula.
any repair (see 21A, Manual gearbox, Manual
gearbox: Precautions for repair, page 21A-1) a Finish cleaning the joint faces using a GREY ABRA-
SIVE PAD part number 77 01 405 943.
a Remove the gearbox (see Manual gearbox: Remo-
val - Refitting) a Use SURFACE CLEANER (see Vehicle: Parts
a Position the gearbox on the component support (see and ingredients for the repairwork) to clean:
21A, Manual gearbox, Gearbox support equip-
ment: Use, page 21A-21) - the joint face of the fifth gear housing,

- the mechanism housing.

II - REMOVAL OPERATION FOR THE FIFTH GEAR
HOUSING
WARNING
To ensure proper sealing, the gasket surfaces
must be clean, dry and not greasy (avoid any fin-
ger marks).

a Parts always to be replaced:

- the O-rings.

II - REFITTING OPERATION FOR THE MECHANISM

COVER

a Fit a new O-ring and fit the fifth gear housing.

117504 a Refit the fifth gear housing.

a Remove the three bolts from the fifth gear housing.
a Torque tighten the fifth gear housing mounting
a Remove the fifth gear housing (1) along the axis of bolts (25 N.m.)
the gearbox, as it contains a lubrication channel lo-
cated in the bore of the primary shaft.
III - FINAL OPERATION

a Remove the gearbox from the component support

(see 2 1 A , Manual gearbox, Gearbox support
equipment: Use, page 21A-21)

a Refit the gearbox (see Manual gearbox: Removal -

Refitting)

21A-62
 MANUAL GEARBOX
5th gear sprockets and synchronisers: Removal - Refitting 21A
X06 – X35, and JB1 or JB3 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64, and JB1 or JB3 – X65, and JB1 or
JB3 – X76, and JB1 or JB3
II - REMOVAL OPERATION OF THE FIFTH GEAR
Essential special tooling PINION AND SYNCHRONISERS
Bvi. 31-01 Set of 3 roll pin drifts (5mm
diameter roll pins).

Bvi. 1170 Extractor for 5th speed gear

hub.

Bvi. 22-01 Extractor body without cover.

Bvi. 1000-01 5th fixed gear extractor.

Bvi. 1175 Bolt for fitting 5th speed fixed

gear.

Tightening torquesm
121104
fifth gear kickdown point 20 N.m a Drive out the pin of the fifth gear fork (1) using the
tool (2) or a roll pin punch (Bvi. 31-01).
input shaft nut 190 N.m

output shaft bolt 80 N.m

REMOVAL

I - REMOVAL PREPARATION OPERATION.

a

Note:
Consult the safety and cleanliness advice and
operation recommendations before carrying out
any repair (see 21A, Manual gearbox, Manual
gearbox: Precautions for repair, page 21A-1)

a Remove the gearbox (see Manual gearbox: Remo-

val - Refitting)
a Position the gearbox on the component support (see
21A, Manual gearbox, Gearbox support equip-
ment: Use, page 21A-21)
a Remove the fifth gear housing (see 21A, Manual
gearbox, 5th gear housing: Removal - Refitting,
page 21A-62)

21A-63
 MANUAL GEARBOX
5th gear sprockets and synchronisers: Removal - Refitting 21A
X06 – X35, and JB1 or JB3 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64, and JB1 or JB3 – X65, and JB1 or
JB3 – X76, and JB1 or JB3
Removing the fifth gear hub:

92957 121101
a Shift to first gear using the gear lever (3) . a Position the (Bvi. 1170)
a Change into fifth gear by sliding the fifth gear fork a Turn the tool in order to position the grooves of the
along its shaft. tool selector rod opposite the fifth gear hub.
a Remove the fifth gear hub.
Note:
The aim of this operation is to lock the shafts in
order to make loosening easier.

a Remove:
- the output shaft bolt and its fixed washer (7) ,
- the washer (8) ,
- the input shaft nut (6)
- the fifth gear fork and selector rod assembly (4)
a Remove the fifth gear kickdown point (5) .

Note:
When removing the fifth gear kickdown point,
recover one or both 0.30mm washers.

21A-64
 MANUAL GEARBOX
5th gear sprockets and synchronisers: Removal - Refitting 21A
X06 – X35, and JB1 or JB3 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64, and JB1 or JB3 – X65, and JB1 or
JB3 – X76, and JB1 or JB3
Removing the fifth fixed gear: REFITTING

I - REFITTING PREPARATION OPERATION

a Clean the joint faces of the mechanism housing
using SUPER CLEANING AGENT FOR JOINT FA-
CES (see Vehicle: Parts and ingredients for the
repairwork) .

WARNING
Do not scrape the joint faces of the aluminium,
any damage caused to the joint face will result in
a risk of leaks.

a Remove the residue using a plastic spatula.

a Finish cleaning the joint faces using a GREY ABRA-
SIVE PAD part number 77 01 405 943.
a Use SURFACE CLEANER (see Vehicle: Parts
and ingredients for the repairwork) to clean:
121102
- the shaft ends,
- the mechanism housing.

WARNING
To ensure proper sealing, the gasket surfaces
must be clean, dry and not greasy (avoid any fin-
ger marks).

a Parts always to be replaced:

- the O-ring,
- the pin of the fifth gear fork.

121103

a The fifth fixed gear is removed using the (Bvi. 22-01)

and (Bvi. 1000-01).

a Fit the output shaft bolt and its washer (9) and tigh-
ten it 4 or 5 turns.

a Fit a half-shell of tool (10) Bvi. 1000-01 under the

fifth gear pinion.

a Fit the extractor (11) Bvi 22-01

a Fit the other half-shell

a Remove the fifth gear pinion.

21A-65
 MANUAL GEARBOX
5th gear sprockets and synchronisers: Removal - Refitting 21A
X06 – X35, and JB1 or JB3 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64, and JB1 or JB3 – X65, and JB1 or
JB3 – X76, and JB1 or JB3
II - REFITTING OPERATION FOR THE FIFTH GEAR - the fifth gear hub (16) fitted with its synchroniser
SYNCHRONISERS AND PINION spring.

93462 92957
a Apply three drops of LOCTITE FRENBLOC to the a
grooves on the fifth fixed gear.
Place:
a Fit the fifth fixed gear using the tool (12) (Bvi. 1175).
- the fifth gear fork and selector rod assembly (17) ,
- the input shaft nut (18)
- the output shaft bolt (19) .
- the fifth gear kickdown point coated with sealing re-
sin (20) .

Note:
When refitting the fifth gear kickdown point, refit
one or both 0.30mm washers.

a Torque tighten the fifth gear kickdown point (20

N.m).

114287
a
On the input shaft, refit:
- the lock washer (13) ,
- the idle gear supporting ring (14) ,
- the fifth idle gear (15) with its synchroniser ring,

21A-66
 MANUAL GEARBOX
5th gear sprockets and synchronisers: Removal - Refitting 21A
X06 – X35, and JB1 or JB3 – X40 – X42 – X44 – X48 – X53 – X56 – X57 – X64, and JB1 or JB3 – X65, and JB1 or
JB3 – X76, and JB1 or JB3
III - FINAL OPERATION
a Refit the fifth gear housing (see 21A, Manual gear-
box, 5th gear housing: Removal - Refitting, page
21A-62)
a Remove the gearbox from the component support
(see 2 1 A , Manual gearbox, Gearbox support
equipment: Use, page 21A-21)
a Refit the gearbox (see Manual gearbox: Removal -
Refitting)

92957

a Shift to first gear using the gear lever (21) .

a Change into fifth gear by sliding the fifth gear fork

along its shaft (22) .

Note:
The aim of this operation is to lock the shafts in
order to make loosening easier.

tighten to torque:

- the input shaft nut (190 N.m)

- the output shaft bolt (80 N.m)

a Shift into neutral.

121104

a Refit the fifth gear fork pin.

21A-67