Unscrew the plug, remove the pin and the retainer spring. Loosen the bolts securing the gearbox housing to the clutch housing. If necessary, hit with a plastic mallet around the perimeter of the upper part of the crankcase (near the bearings and at the ends of the primary and secondary shafts. Remove magnetic washer (pic. 3.15), do not drop the puck, as it may break.
Remove fork axle (pic. 3.16) and its spring.
Remove the shift forks, then the locking bracket (pic. 3.17).
Remove input and output shafts and reverse idle gear at the same time (pic. 3.18).
Remove differential assembly (pic. 3.19).
Remove the input shaft bearing from the clutch housing in the following order: using a screwdriver, remove the bearing rollers one by one, then break the plastic separator (pic. 3.20), using puller 16.021 and 15.053, press out the outer race of the bearing (pic. 3.21).
Press out the wheel drive shaft seals, preferably using a special puller 21.051 (pic. 3.22) and outer rings of differential bearings.
The outer ring of the bearing, installed in the smaller part of the differential box, abuts against two elastic washers. Their position must be remembered: the smaller washer is mounted against the seat, the convex side to the convex side of the larger washer, the smooth side of which is in contact with the outer ring of the bearing, as shown in fig. 3.23.
Razboka secondary shaft
Fix the output shaft in a vice with soft pads in a vertical position supported by the final drive gear (pic. 3.24).
Consistently remove and lay: retaining ring, shaft bearing, having previously installed the retaining ring in the groove (pic. 3.25), 4th gear gear, retaining ring, 3rd and 4th gear synchronizer hub and clutch with blocking rings, 3rd gear gear, synchronizer blocking ring and thrust half rings. 2nd gear gear (pic. 3.26), 1st and 2nd gear synchronizer hub and clutch with blocking rings, synchronizer hub retaining ring and 1st gear gear.
Disassembly of the input shaft
The input shaft with gears is made in one piece, so only its bearings are removed using a universal double-lever puller. When removing the bearing from the 4th gear side, start the tabs of the puller levers by the adjusting ring installed in the groove of the outer ring of the bearing.
Differential disassembly
Remove the mandrels to hold the planetary gears and remove these gears by tilting the differential case. Remove the retaining ring of the pinion axle and remove the pinion gears. Using a universal double-lever puller, press out the bearings, put marks on them in order to install them in their original places during assembly. Remove the speedometer drive gear. Loosen the bolts securing the driven gear of the final drive and remove it, using a plastic mallet if necessary. Remember the position of the gear on the box: the bevel of the teeth towards the differential.
Features of dismantling a five-speed gearbox
After removing the fork and the clutch release bearing, unscrew the latch 1 (pic. 3.27) selector rod, remove the detent pin and spring. Unscrew the fasteners carefully, as they are spring loaded.
NOTE: From model year 1984 on all vehicles «Escort» with four- and five-speed gearboxes, phosphated detents were installed to facilitate gear shifting on hot gearboxes. These retainers are painted black instead of the steel color of the older retainers.
Unscrew ten bolts and remove the gearbox cover. Remove the 5th gear lever (pic. 3.28).
Remove the retaining ring and 5th gear, as well as the synchronizer and 5th shift fork assembly. Remove circlip and 5th gear from input shaft using puller 16.035. Discard retaining ring. Loosen the nine bolts securing the crankcase of the 5th gear (pic. 3.29) and take it off.
Remove the circlips from the main and output shaft bearings. Unscrew the three nuts securing the gearbox bracket and remove the bracket. Remove the magnetic washer remove the circlip from the fork axle bushing (pic. 3.30), remove the shift fork of I and II gears, remove the bushing.
Pull out the input and output shafts and the reverse idle gear at the same time. Remove locking bracket. Remove differential box assembly.
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