DRIVETRAIN C549 37 H. TRANSAXLE AS+SEMBLY INSTALLATION 1. Fit the guide pin for fitting Reverse and secure it with exterior staking. 2. Fit the differential mounting bearing outer races (1a) using tools (1b) 287458902617 (Fitting tool) and (1c) 287458902618 (Grip). 3. Fit the magnet (1). 4. Fit the lay shaft (2) front bearing. 5. Fit the differential (3) assembly. 6. Fit the reverse idler gear (4). NOTE: Make sure that the gear engagement teeth are facing downwards. 7. Fit the main and lay shaft assemblies (5) at the same time. 8. Fit the gear engagement safety pawls using a suitable drift. 9. Fit the 5th speed and reverse drive rod (1). 10.Fit the 3rd - 4th speed control fork (2a) and the control rod (2b). 11.Place the safety pawl on the rod before fitting it in its housing 12.Remove the 1st-2nd speed drive rod (3a) together with the fork (3b). NOTE: To facilitate installation, move the 1st2ndspeed control rod in the arrowed direction. 13.Tighten the M6 bolts securing the 1st-2nd speed control forks (4a) and the M6 bolts 3rd4th speed control rods (4b), both to a specified torque of1.5 ~ 1.9 da Nm. 14. Fit the reverse control fork mounting bracket (5a) and secure it tightening the M6 bolts (5b) to torque of 8.5 ~ 11.1 da Nm. 15.Place all the gear control forks in neutral. 16.Apply sealant to the contact surfaces between the manual TRANSAXLE bell housing and the TRANSAXLE casing. 17.Fit the TRANSAXLE casing on the manual TRANSAXLE bell housing. NOTE: Keep the gear selector/engagement lever upwards and check that the gear selector engages in the 3rd-4th speed control fork. 18.Tighten the TRANSAXLE casing M8 bolts to Torque of 2.1 ~ 2.6 Kgm 19.Fit the gear control rod positioning plugs 20.Tighten the reverse shaft M8 bolt to the recommended torque of 2.9 ~ 3.6 Kgm. 21.Fit the reversing light switch. 22.Fit the main and lay shaft rear bearing circlips.
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