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5th gear conversion



Excerpted from my meatball site... (the bullets are gone, sorry about the readability).  A few
more details:

-Front, rear, and pass. mounts come off.
-Jack the drivers side of the car up HIGH.
-Drop the tranny far enough so the 5th gear cover comes off with minimal interference.
-DON'T PULL THE SHAFT OUT...this is why you jack the car so high, so the shaft is not so much
downhill, sliding out on it's own.
-You don't have to remove the shifter assy, just have a helper apply the brakes when you gronk off
the bolt in the end of the mainshaft.
-Installation is the reverse of disassembly  ;)

HTH, 

Ron
Now we have the 5th gear cover ready to come off, that should be pretty obvious.  After you remove
it, you'll see the 5th gears and forks staring at you.  Also, a rod sticking out of a hole.  Do
yourself a favor, DON'T remove that rod yet.  We'll work around it and remove it later. Just a
note, this is the rod that all the shifter forks ride on.  Pull it out and you'll HAVE to split
the case because once those forks all fall away from where they belong (and boy do they), you're
screwed.  I've made a few bucks just putting these back in for folks. 

Next step is to get 5th gear off.  The big bolt on the ass end of the mainshaft has to come off,
but it's torqued to about 130ft-lbs.  You'll spin the gearbox if you put a wrench on it so we have
to lock the gearbox against itself.  That's really why we took the shifter assembly out, so we can
move the forks around (another reason to NOT remove that shaft I told you about!) and engage two
gears at once. You'll see the fingers in there, just push and turn the tranny until any gear falls
in, then engage 5th from the slider you see.   

Now, suppose you really screwed up and did pull that shaft out.  And you can't lock the gearbox so
you can remove the nut.  What to do?  Well, I have put a penny between the 5th gears on scrap
trannies to lock things up.  It worked but even I wouldn't try this for good gearboxes and expect
5th to live.  Those gears are hard as hell but as you know, steel gives us brittleness when
hardened, as gears are, and you can break a tooth off.  It's not difficult. 

To get the bolt off,  you'll need a 12mm triple square bit - the same one that fits cylinder head
bolts. IT'S NOT A TORX!!  DON'T TRY.  Lisle sells a A "Triple Square" bit set in a 3-pack that
contains what you need. Large is for 5th gear (also head bolts), small is for mainshaft rear
bearing, medium is for inner CV-flange bolts.  This image was stolen without permission from
http://www.thetoolwarehouse.net/shop/LIS-60750.html, so buy your stuff from them.  Yes I know it's
a 4-pack but what I've bought locally is always a 3-pack.  Go figure. 

Now, actually removing the bolt, which is butt-tight, wrap the end of a long bar in a shop towel,
then put that into the bore where the shifter mechanism came out of. I brace that against my body
while I tug on the breaker bar. Be careful that no pressure rests on the clutch cable perch or (I
guess) there's a chance you could break it off...I haven't done this. 

On to removing 5th gears.  There's a lock plate that holds the 5th gear fork adjustment in place. 
Gradually and gently pry it up and free.  Then unscrew the adjustment until it's free.  SURPRISE! 
It's a left-handed thread.  There’s a special tool for adjusting/removing/installing the 5th gear
shifter fork - a simple cylinder with a two tits on the end.  I have no decent homebrew
substitute, but I have used small channellocks with success. 

Now, you can remove 5th gears.  A nail puller is handy to pry them off - just protect the case
mating surface with something.  A little heat may help too. 
As you pull off 5th gear, you will have to move all sliders back into neutral position, because
the shafts will want to rotate with the helix of the gears.  Also, you should strive to keep the
hub/slider/synchro assembly together.  It makes things a lot easier to reassemble. 

--- Euroroc II <flaatr@yahoo.com> wrote:
> Anyone (Ron?) write up a procedure on how to swap 5th gears on 020 trannys? 
> I really need to do this but I don't want to pay a lot of $$$ to have it 
> done if it is as easy as I have heard.
> 
> I figure I can get the gear sets from another 020 in a yard and replace 
> then 0.91 in my AGB for a lot cheaper than purchasing the Autotech set... 
> or is this the way to go?
> 
> -Raffi trying to be like my hero Cheapass
> 
> 
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> Scirocco-l@scirocco.org
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