SAMAND

(XU7JPL3)

Service Manual
Manual Gearbox
 Product:
Chapter: Section: SAMAND XU7JPL3
Manual Gearbox

SAMAND
Service Manual

Foreword:

This Service Manual contains descriptions of the following categories for the
Samand:
- Gearbox
- Clutch
- Drive shafts
- Gear change linkage mechanism
This manual should be used as service manual and s workbook for
training instructors and technicians. We reserve the right to introduce
change without prior notice.

II
 Contents
Gearbox
Technical data
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Special tools
Input shaft rear bearing outer race remove/refit drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Differential bearings fitting tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Output shaft front bearing/input shaft rear bearing outer race fitting tube . . . . . . . . . . . . . . . 5
Input shaft front and rear bearing/output shaft rear bearing fitting tube . . . . . . . . . . . . . . . . . 6
Thrust buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Input shaft bearing pre-loading shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Differential bearings pre-loading shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Right-hand output oil seal fitting drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Clutch fork lever key extracting adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Release bearing guide oil seal fitting drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5th speed synchro hub extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Differential seal mounting plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Differential seal mounting plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Left-hand output oil seal fitting drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Right-hand output oil seal fitting drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Reduction gear shaft right-hand bearing fitting tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Slide hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Facom U53 T2 extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5th gear extractor claw and extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gearlever pin extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pin fitting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Technical description
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Basic design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Special features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Obturators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Gear controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Reverse rockers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Adjustment and replacement

Gearbox remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Gearbox refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Gearbox disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Gearbox.assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Disassemble in situ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
 Assemble in situ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Input shaft bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Input shaft overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Output shaft overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Differential overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Right-hand drive shaft oil seal replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Left-hand drive shaft oil seal replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Input shaft oil seal replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Selector shaft oil seal replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Reverse light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Speedometer drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Oil replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Clutch
Technical data
Pressure plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Driven plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Special tools
Plate centralising mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Technical description
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Adjustment and replacement

Clutch overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Clutch release mechanism overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Clutch cable replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Clutch pedal replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Drive shafts
Technical data
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Special tools
Differential seal mounting plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Differential seal mounting plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
AY hub clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Ball joint extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
 Technical description
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Constant velocity joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Adjustment and replacement

Driveshaft remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Driveshaft refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Rubber gaiter replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Intermediate bearing replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Gearchange mechanism
Technical data
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Technical description
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Adjustment and replacement

Gearlever / Gearlever housing replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Gear linkage overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Lever knob and gaiter replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
 1

Gearbox

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 Technical data 3

Technical data
Torque settings

W75S001

Gearbox rear cover 12.5 Nm Gearbox drain plug 10 Nm

Input and output shaft nuts 50 Nm Final drive drain plug 30 Nm
Bearing retaining bolt 15 Nm Speedometer drive support 12.5 Nm
Shaft stop plate bolt 15 Nm Final drive casing extension 20 Nm
Gearbox casing 13 Nm Crown wheel to differential box 65 Nm
Reverse shaft stop plate bolt 20 Nm Final drive casing 10mm bolts 40 Nm
Selection and engagement shaft bracket 15 Nm Final drive casing 7mm bolts 12.5 Nm
Reverse fork 20 Nm Release bearing guide 12.5 Nm
Breather 15 Nm Common level plug 20 Nm
Reverse lamp switch 25 Nm
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4 Technical data

Identification

1 2

W75S002

1 Location of gearbox reference.

2 Self adhesive label fitted for factory assembly use.

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 Special tools 5

Special tools
Input shaft rear bearing outer
race drift
(-).0317A

T(-).0317A

Differential bearings fitting tube

(-).0317D

T(-).0317D

Output shaft front bearing, input

shaft rear bearing outer race
fitting tube
(-).0317E

T(-).0317E

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6 Special tools

Input shaft front bearing and rear

bearing/output shaft rear bearing
fitting tube
(-).0317F

T(-).0317F

Thrust button
(-).0317J

T(-).0317J

Thrust button
(-).0317Z

T(-).0317Z

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 Special tools 7

Input shaft bearing pre-loading

shim
(-).0317K

T(-).0317K

Left-hand output oil seal fitting

drift
(-).0317T

T(-).0317T

Right-hand output oil seal fitting

drift
(-).0317U

T(-).0317U

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8 Special tools

Clutch fork lever key extracting

adaptor
(-).0317V

T(-).0317V

Release bearing guide oil seal

fitting drift
(-).0317W

T(-).0317W

5th speed synchro hub extractor

(-).0317Y

T(-).0317Y

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 Special tools 9

Differential seal mounting plug

(-).0317G

T(-).0317G

Differential seal mounting plug

(-).0317S

T(-).0317S

Left-hand output oil seal fitting

drift
(-).0326D

T(-).0326D

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10 Special tools

Right-hand output oil seal fitting

drift
(-).0326E

T(-).0326E

Reduction gear shaft right-hand

bearing fitting tube
(-).0326J

T(-).0326J

Slide hammer
(-).0316A

T(-).0316A

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 Special tools 11

Extractor
Facom U53 T2

Facom U53 T2

5th gear extractor claw and

extractor
(-).0331-F&A

T(-).317F,A

Gearlever pin extractor

(-)0317-AL

T(-).0317AL

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12 Special tools

Pin fitting tool

(-).0317-AM

T(-).0317AM

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 Technical description 13

Technical description
System overview

W75D001

The gearbox is designed for front wheel drive and

forms a unit with the engine. The drive unit is
transversely mounted in the car, which gives good
cooling and the shortest possible route for the transfer
of power to the drive wheels. This location also
contributes to a compact engine compartment. The
gearbox has five forward gears, all of which have
synchromesh.

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14 Technical Description

Basic design

9 8 7 6 5
3
4

a 2 1

15

16
17 18

10 11 12 13 14

19 b 20 21
W75D002

1 Input shaft 13 1st-2nd synchroniser

2 Release bearing guide 14 1st speed driven gear
3 Gearbox and final drive casing 15 Lay shaft
4 Reverse idler gear 16 Crown wheel
5 3rd speed driving gear 17 Planet wheels
6 3rd-4th synchroniser 18 Sun wheels
7 4th speed driving gear 19 Differential housing
8 5th speed driving gear 20 Counter screw
9 5th speed synchroniser 21 Extension
10 5th speed driven gear Adjustment shims:
11 3rd-4th speed driven gear a. 18 shims from 0.7 to 2.4mm - in 0.1mm steps
12 2nd speed driven gear b. 12 shims from 1.1 to 2.1mm - in 0.1mm steps
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 Technical description 15

Special features

W75D003

1 Heavy duty ribbed casing

2 Heavy duty sun and planet wheels
3 Single pin differential cross shaft pin in blind hole
4 Reduction gear fitted on opposite side of
differential housing to standard crown wheel

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16 Technical description

Obturators

1 2

4 3

W75D004

1 Protector
2 Obturator
3 Lower opening obturator
4 Rear gearbox obturator

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 Technical description 17

Gear controls
1 1 One-piece engagement shaft and lever
A “Cassette” assembly comprising:
2 Sleeve
3 Reverse engagement finger
4 1st-2nd, 3rd-4th and 5th engagement finger
3
5 4 7 5 Interlock key
6 7 6 Spring
7 Cups

W75D006

Reverse rockers
5th speed rocker.

W75D007

Lubrication
1 Drain plug.
2 Gearbox and final drive filler and level plug
The gearbox is equipped with two plugs, these are
used for work on the gearbox which requires the oil to
be drained. When checking level or topping up, the
filler/level plug is removed and oil is topped up until it
flows out of the level plug. A dry gearbox has a
capacity of 1.9 litres of oil.

2
1
W75D008

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 Adjustment and replacement 19

Adjustment and replacement

Gearbox remove
To remove
1 Special tools
2 1 Crossbeam and adjusting screw.(-).0911A1.
2 Crossbeam support (-).0911 A2.
3 Lifting hook.(-).0102J.
4 Fitting drift for final drive right-hand output oil seal
4 (-).0317U.
5 5 Fitting drift for final drive left-hand output oil seal
(-).0317T.
3 6 Ball joint extractor (-).0709.
6

W75R167

1 Disconnect and remove the battery and it’s

supporting tray (see book 11).
2 Release two clips and Remove air intake pipe.
3 Remove three nuts and move aside the ECU
mounting box.
1 4 Disconnect the clutch cable from the gearbox (see
page 89).
Note: Record the location of all connecting cables and
sensors for reassembly.

3 W75R168

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20 Adjustment and replacement

5 Release the reverse light sensor connector and

move aside the cables from the gearbox, make a
note of the run of the cable for refitting (see page
6 75).
6 Disconnect gear linkage rods from the gearbox.

6
6

W75R169

7 Remove two bolts starter motor to gearbox.

8 Separate the starter without disconnecting it.

W75R170

9 Support vehicle in lift and remove front wheels.

10 10 Raise vehicle, remove two nuts and three bolts
and engine undertray.

W75R171

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 Adjustment and replacement 21

11 Release clutch cable from lower left wheel arch

liner and remove two screws wheel arch liner to
bumper, one nut and three press fittings to wheel
arch, one screw to front framework and remove
wheel arch liner.

W75R172

12 Remove bolts from anti-roll bar drop link to lower

suspension arms on both sides of the vehicle.
13 Disconnect both lower suspension arms from the
hub carriers using (-).0709 ball joint extractor.
14 Drain the gearbox (see page 77).
12
13

13
W75R173

15 Remove centre bolt from engine to subframe

18 mounting
16 loosen two intermediate bearing retaining bolt
16 nuts.
16 17 Rotate retaining bolts 90Þ so offset heads are
clear of bearing outer race.
18 Pull hub carrier assembly outward, pull inner
driveshaft to free intermediate bearing from
mounting bracket.
19 Pull Left-hand hub carrier assembly outward to
disengage left-hand drive shaft from differential.
Note: Support the driveshafts to avoid damage.
15

W75R174

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22 Adjustment and replacement

20 Remove the heat shields from the speedometer

drive housing.
21 Remove the speedometer drive cable retaining
21 pin and withdraw the cable.
22 Remove the electrical connector from the
speedometer drive.

20

21

W75R175

23 On vehicles with air-conditioning, remove nut and

fixing plate and move aside air-conditioning pipes.

23

W75R176

24 Remove three bolts and clutch housing plate.

25 Remove gearbox to engine bottom fixing bolt.
26 26 Remove two bolts and connector fixing bracket.

25

24
W75R177

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 Adjustment and replacement 23

27 Attach crane to gearbox using (-).0102J.

28 Remove the nut from left hand engine mounting
28 and recover the washer.
29 Remove two nuts and left hand gearbox mount.
30 Remove gearbox mounting shaft and washer.
30
29
29

W75R178

31 Lower the engine as far as possible without

straining the right-hand engine mounting. Move
the gearbox end forward as far as possible.
32 32 Hold the engine in position with cross beam
(-).0911 A1 fitted with supports (-).0911 A2.
33 Remove all remaining engine to gearbox
mounting bolts.
Note: Record the correct fitted position of each bolt,
and the necessary brackets, as they are removed to
use as reference on refitting.
34 Move the gearbox to the left to free it from location
dowels then pivot the differential end of the gearbox
upwards to disengage it from the subframe.
35 Lower the gearbox from the vehicle and collect
the location dowels from either the gearbox facing
W75R179
or engine.

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24 Adjustment and replacement

Gearbox Refit
To fit
On refit always replace:
- The final drive output oil seals using (-).0317U
and (-).0317T.
- Self locking nuts.
Coat lightly with grease:
- Gearbox input shaft splines
- Release bearing guide sleeve.
- Fingers of the selection fork.
Warning: Verify that the clutch release bearing is
present. Ensure that all bell housing dowels are fitted.

1 Slowly raise the gearbox into position using crane

(-).0102J and position gearbox facing to engine.
Be sure the bell housing is correctly position with
the location dowels.
2 Refit engine to gearbox mounting bolts following
the positions of each bolt noted on removal.
3 Carefully raise the crane while pushing the engine
and gearbox back to its correct position.

W75R180

4 Refit gearbox mounting shaft and washer.

5 Refit left-hand gearbox mount and it‘s two nuts,
6 tighten to 23Nm.
6 Replace washer and nut to the mounting shaft on
the left-hand gearbox mounting, tighten to 65Nm.
4 7 Detach the crane from the gearbox and remove
5
5 the cross beam (-).0911 A1 and its supports
(-).0911 A2.

W75R181

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 Adjustment and replacement 25

8 Position connector fixing bracket and replace two

bolts.
8 9 Refit gearbox to engine bottom fixing bolt.
10 Position clutch housing plate and replace three
bolts, tighten to 10Nm.

10
W75R182

11 On vehicles with air-conditioning, position

air-conditioning pipes and refit fixing plate
and nut.

11

W75R183

12 Refit the electrical connector to the speedometer

drive.
13 Refit the speedometer drive cable and secure by
13 fitting the retaining pin.
14 Replace the heat shield to the speedometer drive
housing.

14

13

W75R184

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26 Adjustment and replacement

15 Engage left-hand inner velocity joint into the

16 differential and carefully push the hub carrier to
force the driveshaft into position.
17 16 Engage right-hand inner velocity joint into the
17 differential and locate the intermediate bearing in
the housing and carefully push the hub carrier to
force the driveshaft and bearing into position.
17 Rotate retaining bolts 90Þ so there offset heads
are holding the bearing outer race and replace the
nuts, tighten to 20Nm.
18 Refit the engine to subframe mounting centre bolt.

18

W75R185

19 Refil the gearbox oil (see page 77).

20 Replace nuts to both lower suspension arms to
hub carriers, tighten to 250Nm.
21 Positon both anti-roll bar drop links to lower
21 suspension arms and replace nuts, tighten to
65Nm.

20 W75R186

22 Replace left-hand wheel arch liner with two

screws wheel arch liner to bumper, one nut and
three press fittings to wheel arch, one screw to
front framework and refit clutch cable to inside of
lower wheel arch liner.

W75R172

Peykan
 Adjustment and replacement 27

23 Position engine undertray then secure firmly with

23 two nuts to front framework and three bolts to
subframe.
24 Replace road wheel and tighten bolts to 85Nm.

W75R187

25 Position the starter motor and refit two bolts.

25

W75R188

26 Connect the gear linkage rods from the bellcrank,

ball and socket assembly to the gearbox.
27 Replace the reverse light switch connector and
26 position cables around the gearbox following the
notes made on removal.

26
26

W75R189

Peykan
28 Adjustment and replacement

28 Replace the clutch inner cable into the mounting

on the gearbox.
29 Replace the clutch outer cable into the clutch
release lever.
28

29

W75R190

30 Position ECU mounting box and replace three

nuts.
31 Position air intake pipe and secure by tightening
two clips.
32 Refit the battery support tray and refit and
32 connect battery (see book 11).

31

30 W75R191

Peykan
 Adjustment and replacement 29

Gearbox disassemble
To disassemble
1
Before disassemble:
- Remove gearbox from vehicle
- thoroughly clean the gearbox casing
1 Remove six bolts and oil filler/level plug, and
remove rear cover.

W75R166

2 Engage 5th speed and remove selection fork

retaining pin.
4 5 3 Engage another gear to lock the shafts.
2 4 Remove nut from the input shaft.
5 Remove circlip from the 1st/2nd, 3rd/4th fork
shaft.

3
W75R001

6 Extract the 5th speed hub using (-).0317Y.

W75R002

Peykan
30 Adjustment and replacement

7 Remove the selection fork.

Note: Take care the locking ball in the 5th speed fork
does not escape.
7

W75R003

8 Refit the 5th speed sleeve and hub without the

fork.
8
10 9 Engage 5th speed.
10 Remove nut from output shaft.

9
W75R004

11 Mark the position of the hub in relation to the 5th

11
speed sleeve
12 12 Remove the 5th speed sleeve and hub.
13 Remove 5th speed driving gear using tool
(-).0331F and A.
14 Remove driving gear bush.
15 Remove spacer shim.
13

14
15

W75R005

Peykan
 Adjustment and replacement 31

16 Remove outer shaft bearing retaining bolts.

17 Remove stop ring (if necessary use two tapered
points to lift ring free).
18 18 Remove bolt and shaft stop plate.
19 Remove reverse idler shaft retaining bolt.
20 Remove gearbox casing fixing bolts
16 21 Remove gearbox casing (tap casing with mallet to
17 free it from ring dowels).

16 20
19

W75R006

22 Engage reverse gear.

23 Remove reverse idler shaft and gear.

22
23

W75R007

24 Twist and remove the 5th speed selection shaft.

24

W75R008

Peykan
32 Adjustment and replacement

25 Twist and withdraw 1st/2nd, 3rd/4th fork shaft.

25

W75R009

26 Pivot and remove the 3rd/4th fork.

27 Fully pull out the engagement lever and
immobilise it in this position on the final drive
casing by turning it downward.
28 Lift the interlocking key.
26

27
28

W75R010

29 Remove 1st/2nd gear and fork assembly.

29

W75R011

Peykan
 Adjustment and replacement 33

30 Remove reverse rocker.

31 Remove locking finger.
33 32 Remove spring.
33 Remove reverse lamp switch.
34 Retrieve the magnetic plate.
30
31
32
34

W75R012

35 Remove the pin from the engagement shaft using

(-).0317-AL.
36 Drive out tension pins from selection lever and
engagement finger.
37 Remove the engagement shaft.
38 Retrieve the cassette assembly comprising:
- The reverse engagement finger
- The interlock key
- The engagement finger
- The spring and two cups
Warning: The cassette assembly cannot be
dismantled.
39 Remove the output shaft bush.

40 Using clutch fork lever key adaptor (-).0317V and

slide hammer (-).0316A extract the key from the
clutch fork.
41 Remove lever.
42 Remove shaft.
43 43 Remove bearings.
40
41
43
42

40

W75R014

Peykan
34 Adjustment and replacement

44 Remove the engagement shaft oil seal.

45 Remove two screws and selection spring support.
Note: The selection lever can only be removed after
complete dismantling of the final drive.
45 46 Remove centralising dowels.

46
44

46

W75R015

47 Remove three bolts and remove release bearing

guide.
48 Remove adjusting shim from the input shaft.
49 Remove the bearing outer race.
50 Using a screwdriver carefully remove the release
50 bearing guide oil seal.
49
48

47

47 W75R016

51 Remove the input shaft rear bearing outer race

using (-).0317A.

51

W75R017

Peykan
 Adjustment and replacement 35

52 Remove screw, washer and speedometer drive.

53 Remove three bolts and drive housing.
54 Remove ‘O’ ring from drive housing.
55 Remove speedometer gear.
52
56 Remove locating shim.

53

56 55 5453
W75R018

57 Remove ten screws and differential half casing.

57

57
57

57
57

57
W75R019

58 Remove differential from gearbox casing.

59 Remove selection lever.
60 Remove casing centralising dowel.
58
60

59

W75R020

Peykan
36 Adjustment and replacement

Gearbox assembly
To assemble
Before assembly:
- Parts and housing should be thoroughly washed
before assembly.
- Check the parts for wear. Change damaged or
defective parts.
- If a lot of swarf in the gearbox, all bearings should
be replaced. Always change both bearings on an
axle, even if only one is damaged.
- Change all drive shaft seals.
- Oil all bearings and friction surfaces before
assembly.

1 Refit differential casing centralising dowel.

2 Refit the selection shaft.
3 Apply a suitable sealing compound.
4
4 Position the differential.

W75R021

5 Refit the differential half casing and loosely fit its

bolts.
6 Refit locating shim.
7 Refit speedometer gear.
10 8 Refit ‘O’ ring.
9 Refit speedometer drive housing and bolts to
20Nm to align the joint faces.
10 Refit speedometer drive, washer and screw,
tighten to 12.5Nm.

6 7 8 9
W75R023

Peykan
 Adjustment and replacement 37

11 Refit left-hand oil seal using (-).0317T fitting drift.

Gently force seal by applying pressure with a
mallet.

11

W75R024

12 Refit right-hand oil seal using (-).0317U fitting

drift. Gently force seal by applying pressure with a
mallet.
13 Tighten differential half casing bolts:
- 10mm bolts 40Nm.
- 7mm bolts 12.5Nm.

12

W75R025

14 Refit input shaft rear bearing.

14
W75R026

Peykan
38 Adjustment and replacement

15 Refit release bearing guide without the paper joint

and without tightening it and refit the input shaft
front bearing outer race.
16 16 Refit selection spring support and two bolts,
tighten to 1.5Nm.
17 17 Refit two casing centralising dowels.
18 Refit engagement shaft oil seal.
18

15
17

W75R027

19 Position the cassette assembly.

20 Position engagement shaft.
21 Fit special tool (-).0317-AM.
22 Position a new tension pin, and screw in threaded
rod fully to position pin.

23 Lubricate and refit selection shaft oil seal.

24 Refit washer.
25 Refit spring.
26 Refit selection lever.
23 27 Refit new tension pins.
24
25
26

27

W75R029

Peykan
 Adjustment and replacement 39

28 Refit spring and reverse locking finger.

29 Compress the reverse locking finger assembly to
engage the shaft, fork and fixing bolt, tighten to
30 25Nm.
30 Refit reverse lamp switch with a new copper
washer, tighten to 25Nm.
29 31 Refit the magnetic plate.
28
31

W75R030

32 Fully pull out the engagement lever and

33 immobilise it in this position on the final drive
casing by turning it downward.
33 Lift the interlock key.
32

W75R031

34 Couple the input and output shafts with the

1st/2nd fork.
35 35 Locate the gears in the casing.
36 Engage reverse gear.

36

W75R032

Peykan
40 Adjustment and replacement

37 Refit reverse idler shaft and gear, Tooth lead

should be downward with the shaft locating pin
protruding 5mm.

37

W75R034

38 Engage neutral and refit 5th speed fork shaft.

38

W75R035

39 Refit gearbox casing and fixing bolts, tighten to

12.5Nm.
41
40 Refit reverse shaft securing bolt and new washer,
43 tighten to 20Nm.
41 Refit shaft top plate and bolt, tighten to 15Nm.
42 Refit bearing stop ring.
42 43 Refit two bearing securing bolts and washers,
39 tighten to 15Nm.

40
1

W75R036

Peykan
 Adjustment and replacement 41

44 Refit the distance washer with its shoulder

towards the bearing.
45 Refit 5th speed gear bush.
46 Refit 5th speed driving gear.
47 Refit sleeve and hub without the fork.

47
46
45 44

W75R037

48 Engage two gears, 3rd or 4th using the selector

50 and 5th.
49 Remove the output shaft nut and coat the threads
51,52 with a locking compound.
50 Refit output shaft nut, tighten to 50Nm. Lock it by
turning back the metal into the shaft splines.
51 Remove the sleeve and hub.
52 Locate the 5th speed fork and refit assembly,
observe the marks made on disassembly.

W75R038

53 Position the locking ball and compress it in its

53 bore while lowering the synchromesh assembly.

W75R039

Peykan
42 Adjustment and replacement

54 Engage 3rd,4th or 5th.

55 Apply a thread locking compound to the input
shaft threads.
56 Refit input shaft nut, tighten to 50Nm and lock it
56 56 by turning back the metal into the shaft splines,
and assemble the fork and its shaft with a new
pin.

W75R040

57 Apply sealing compound to the rear casing and

57 58 assemble to gearbox housing tighten bolts to
12.5Nm.
58 Fit new washer and level/filler plug without
tightening it.

57

W75R041

59 Position input shaft bearing pre-loading shim

(-).0317K on the outer race of the bearing and
60 position on input shaft.
59 60 Refit release bearing guide without paper joint.
Progressively tighten the release bearing guide
while turning the input shaft until tight. This
positions the bearing correctly
61 Remove release bearing guide and pre-loading
shim.

W75R042

Peykan
 Adjustment and replacement 43

62 Place the depth gauge on the casing joint face,

release the knob and slde the left hand ruler down
to meet the bearing outer race this will give you
measuement (A) or alternatively use a
micrometer.

62

W75R043

63 Place the depth gauge on the contact face of the

release bearing, release the knob and slde the left
hand ruler down to meet it joint face this will give
you measuement (B) or alternatively use a
micrometer.
64 Subtract B from A and to the result add 0.03mm
to give clearance of 0.08mm + 0.04mm.
63 Note: This value takes into account the thickness of the
paper joint.

W75R044

65 Fit new seal to release bearing guide using

(-).0317W fitting drift.
65 66 Position new shim (dimensions previously
determined).
67 Refit release bearing guide and three bolts,
tighten to 12.5Nm.

W75R045

Peykan
44 Adjustment and replacement

68 Using clutch fork adaptor (-).0317V and slide

hammer (-).0316 refit clutch fork key.

68

W75R046

Peykan
 Adjustment and replacement 45

Disassemble in situ
To remove
Special tools
1
1 Crossbeam and adjusting screw.(-).0911.A1.
2 Crossbeam support (-).0911 A2.
3 5th speed hub extractor (-).0317Y.

2
3

W75R073

1 Disconnect and remove the battery and it’s

supporting tray (see book 11).
2 Disconnect the clutch cable from the gearbox (see
page 89).
3 Support vehicle and remove front left wheel.
4 Remove engine undertray (see page 20).
5 Release clutch cable from lower left wheel arch
5 liner.
6 Drain the gearbox oil (see page 77).

W75R074

7 Remove front left-hand lower wheel arch liner.

(see Page 21).
8 Hold the gearbox in position with cross beam
8 (-).0911 A1 fitted with supports (-).0911 A2.

W75R075

Peykan
46 Adjustment and replacement

9 Remove the nut from left hand engine mounting

and recover the washer.
9 10 Remove two nuts and left hand engine mount.
11 Remove gearbox mounting shaft and washer.

11
10
10

W75R076

12 Lower gearbox until ball joint support contacts the

anti-roll bar.

12

W75R192

13 Remove seven bolts and level/filler bolt from rear

end casing.
14 Remove rear end casing.

14

13 12
W75R077

Peykan
 Adjustment and replacement 47

15 Engage 5th gear with the engagement lever.

16 Remove pin from 5th speed fork.
16

W75R078

17 Mark the relative positions of the synchroniser

sleeve and hub.
18 Lock the gearbox by engaging reverse with the
engagement lever.
19 Remove input shaft nut and fork shaft circlip.
17

17
19

W75R079

20 Remove 5th speed synchroniser hub using

(-).0317Y hub extractor.

20

W75R080

Peykan
48 Adjustment and replacement

21 Remove hub and synchroniser as assembly with

selection fork.
Warning: take care not to allow locking ball and spring
housed in 5th speed selection fork to escape.
21

W75R081

22 Refit hub and synchroniser assembly without

selection fork.
23 Manually engage 5th gear.
24 Loosen output shaft nut.
25 Remove hub and synchroniser assembly.

22,25

24
W75R082

26 Remove 5th speed driving gear.

27 Remove 5th speed gear bush.
28
28 Remove distance washer.

26 27

W75R083

Peykan
 Adjustment and replacement 49

29 Remove bolt and shaft stop plate.

29
30 Remove output shaft rear bearing stop bolts.
30
31 Remove stop ring (if necessary use two tapered
points to lift ring free).

30 31 W75R084

32 Remove reverse idler shaft retaining bolt.

34 33 Remove gearbox casing fixing bolts.
34 Remove gearbox casing (tap with mallet to free it
from ring dowels).

32 33 W75R085

35 Remove the reverse idler shaft and gear.

36 Remove the magnetic plate.
37 37 Remove 5th speed selection shaft.
Note: Pull and pivot the 5th speed selection shaft to
detach it from interlock key.

35 36

W75R086

Peykan
50 Adjustment and replacement

38 Rotate 1st/2nd and 3rd/4th fork selection shaft to

38 disengage ball recesses and remove.
39 Remove input shaft, output shaft, fork and shaft
assembly.
Note: Pivot the forks to detach them from the interlock
key

39

W75R087

40 Remove input shaft bearing outer race.

41 Remove adjusting shim.
42 42 Remove release bearing guide oil seal.

40 41

W75R088

Peykan
 Adjustment and replacement 51

Assembly in situ
Re-assembly
- Parts and casing should be thoroughly washed
before assembly.
- Check parts for wear. Change damaged or
defective parts.
- If a lot of swarf is in gearbox, all bearings should
be replaced. Always change both bearings on an
axle even if only one is damaged.
- Change seals at drive shafts
- Oil all bearings and friction surfaces before
assembly.

Special tools
1 Input shaft oil seal fitting drift (-).0317 W.
2 Basic shim (-).0317 X.
1

W75R089

Note: If parts are replaced on the input shaft then input

shaft bearing adjustment has to be performed (see
1 adjustments).
1 Refit release bearing guide oil seal using
(-).0317 W drift.
Warning: Fit the contact face of the seal towards the
release bearing guide. Apply grease to the space
between the oil seal lips.
2 Refit adjusting shim determined (see adjustments)
or retrieved.
3 Refit input shaft bearing outer race.

3 2

W75R090

Peykan
52 Adjustment and replacement

Assemble the following

Input/output shaft
1st/2nd fork
3rd/4th fork
Note: For detailed description for refitting shaft
assemblies see relevant sections.
4 Lightly grease on shaft splines.

W75R091

5 Refit input shaft, output shaft, and fork assembly.

Note: Pivot the forks to engage them from the interlock
key
6,7
6 Refit the fork control shaft.
7 Rotate 1st/2nd and 3rd/4th fork selection shaft to
engage ball recesses.

W75R092

8 Refit 5th speed selection shaft.

9 Refit the magnetic plate.
8 10 Refit the reverse idler shaft and gear.

10 9

W75R093

Peykan
 Adjustment and replacement 53

Coat clutch housing joint face with sealing paste.

12 11 Check ring dowels are either fitted to gearbox or
casing and Refit gearbox casing
12 Refit gearbox casing fixing bolts to 12.5Nm.

12 W75R094

13 Refit reverse idler shaft retaining bolt to 20Nm.

15 14
14 Refit shaft stop plate.
17
15 Refit bolt to 15Nm.
16 Refit stop ring.
17 Refit output shaft rear bearing stop bolts to 15Nm.

13 17 16 W75R095

18 Remove distance washer with its shoulder

towards the bearing.
18 19 Refit 5th speed gear bush.
20 Refit 5th speed driving gear.
21 Engage 5th with the engagement lever.

20 19

W75R096

Peykan
54 Adjustment and replacement

22 Refit hub and synchroniser assembly with fork.

23 Manually engage 5th gear.
24 Fit new output shaft nut (coat with threadlock
locktite) tighten to 50Nm and lock it by turning
back the metal into the shaft splines.
25 Remove hub and synchroniser assembly.

22,25

24
W75R097

26 Fit the 5th speed fork to the synchroniser and the

hub (observe the marks made on disassemble).

26

W75R098

27 Fit the locking ball and compress it in its location

27 by pushing the hub-synchroniser assembly.
28 Manually engage 5th gear.

W75R099

Peykan
 Adjustment and replacement 55

29 Coat the input shaft threads with threadlock

Locktite
32
30 Refit input shaft nut, tighten to 50Nm and lock it
by turning back the metal into the shaft splines.
31 Fit new fork shaft circlip.
32 Fit new tension pin.

29,30

W75R100

33 Coat steel case joint face with Silicon Class 2

paste.

33

W75R101

34 Refit rear end casing.

35 Replace washer and loosely refit level/filler bolt.
36 Refit seven bolts to 12.5Nm.

34

36 35
W75R102

Peykan
56 Adjustment and replacement

37 Coat threads of gearbox mounting shaft with a

locking compound and refit shaft and washer,
tighten to 50Nm.
37

37

W75R103

38 Using the crossbeam position the gearbox.

39 Refit left hand engine mount.
41 40 Refit two mount nuts tighten to17.5Nm.
41 Refit gearbox shaft nut and washer to 70Nm.
39
40
40

W75R104

42 Connect clutch cable to gearbox (see page 89).

43 Refit and connect battery supporting tray and
battery (see book 11).
44 Fill the gearbox to the correct level (see page 77).
45 Refit front left-hand lower wheel arch liner. (see
page 21)
46 Connect clutch cable to lower left wheel arch liner
46 47 Refit engine undertray (see page 20).
48 Refit front left wheel tighten to 85Nm.

W75R105

Peykan
 Adjustment and replacement 57

Input shaft bearing adjustment

1 Refit adjusting shim using (-).317K pre loading
shim.
2 Refit input shaft bearing outer race.
3 Refit assembled input shaft.
4 Fit Input shaft bearing outer race into gearbox
casing.
5 Refit gearbox casing.
6 Refit gearbox casing fixing bolts, tighten to
12.5Nm.
7 Fit loosely new input shaft nut, with abutment face
outward.

2 1

W75R124

8 Fit dial gauge support.

9 Fit support rod.
10 Fit assembled support.
10 11 Fit dial gauge.
12 Engage clutch cable.
13 Fully compress clutch pedal.

11

8
W75R125

Note: the following procedures are with the clutch pedal

compressed.
8 Rotate input shaft and push back.
9 Zero dial gauge.
10 Pull the input shaft.
11 Read value (A).
a 12 Take second reading and note the higher value
(A).
13 Thickness of basic shim (B) =0.90mm.
14 Operating clearance (C) =0.08mm.
15 (A)+(B)-(C)=Thickness of required adjustment
shim.
Note: all items fitted during tis procedure can no be
removed.
W75R126

Peykan
58 Adjustment and replacement

Input shaft overhaul

To disassemble
Important: A bearing that has been removed must not
be refitted. Always fit new bearings.
1 Protect the end of the shaft with its nut, position
the extractor on the 3rd speed gear, and press off
the bearing using a Facom U53 T2 press,

W75R047

2 Remove the 4th speed driving gear.

3 Remove the bush from the 4th speed driving gear.
4 Remove the synchroniser and hub.
Note: Mark the 4th speed side and the position of the
hub in relation to the synchroniser.
5 Remove the 3rd speed driving gear.

3 2

4
4 5

W75R048

6 Remove the front bearing from input shaft using

an extractor and Facom U53 T2 press.

W75R049

Peykan
 Adjustment and replacement 59

To assemble
Important:
- Oil the parts as they are fitted.
- Observe the matching marks made on
disassembly.
- Observe the relative positions of new
hub/synchroniser assemblies supplied by parts.
- The bearing removed must be replaced by a new
part.
- Always renew nut
- Check the shaft bearing for knocks or scratches,
replace if necessary

1 Refit the input shaft front bearing using (-).0137F

refitting drift.

W75R050

2 Position the rear bearing outer race in casing

using (-).0317A fitting drift.
3 Push bearing outer race into position by applying
pressure with (-).0317E fitting tube and
compression tube.

2
W75R051

Peykan
60 Adjustment and replacement

4 Position the 3rd speed driving wheel.

Caution: Do not interchange the position of 3rd and 4th
speed gears.
5 Position the sleeve and hub, observe the marks
made on disassembly.
6 Line up the marks on synchroniser slippers on the
3rd speed gear side.
8 7 Note: The marks are made flush with the synchroniser.
7 Position the 4th speed driving gear.
5 4 8 Position bush.
5

W75R052

9 Refit input shaft rear bearing using (-).0317F

fitting tube.

W75R053

Peykan
 Adjustment and replacement 61

Output shaft overhaul

To disassemble
4
Important: A bearing that has been removed must not
be refitted. Always fit new bearings.
1 Using a Facom U53 T2 type extractor.
1 Remove 5th speed driven wheel.
2 Remove bearing.
3 Remove 4th and 3rd speed driven gear.
4 Remove 2nd speed driven gear.
5 Remove 2nd speed gear bush.
3 Note: If necessary, separate the 5th speed gear and
2 the bushing using an extractor against the 4th
speed wheel.

5 W75R054

6 Mark the position of the hub in relation to the

synchroniser.
7 Remove the sleeve and hub.

W75R055

8 Remove the 1st driven gear.

9 Remove the needle roller thrust.

W75R056

Peykan
62 Adjustment and replacement

10 Remove the circlip (if required assist removal with

a feeler gauge).

10

W75R057

11 Extract the bearing using an extractor and Facom

U53 T2 press, protect the end of the shaft with
the nut.

11

W75R058

Peykan
 Adjustment and replacement 63

To assemble
Important:
- Oil the parts as they are fitted.
- Observe the matching marks made on
disassembly.
- Check the condition of the shaft bearing surfaces
for damage or scores. If any are present replace
shaft.
- The bearing removed must be replaced by a new
part.

1 Refit bearing using (-).0317E fitting tube.

W75R059

5 2 Refit the bearing circlip.

3 Refit needle bearing thrust race.
4 Refit the 1st speed driven gear.
5 Refit sleeve and hub.
Note: Position according to marks made on
disassembly and tooth lead is toward the 1st speed
gears.
7 6 Refit the 2nd speed driven gear.
7 Refit bush.
6 8 Refit the 3rd/4th driven gears.

2 8
3

4 5 W75R060

Peykan
64 Adjustment and replacement

9 Refit bearing with the groove towards the outside

using (-).0317F fitting tube.

W75R061

10 Refit the 5th speed driving gear with the raised

face towards the bearing.
10 11 Refit a new nut, provisionally tighten.

11

10
W75R062

Peykan
 Adjustment and replacement 65

Differential overhaul
To disassemble
Important: A bearing that has been removed must not
be refitted. Always fit new bearings.
1 Remove the bearings, using (-).0137D thrust
button and facom U53 T2 type extractor.

W75R063

2 Remove 8 crown wheel bolts.

3 Remove crown wheel from differential housing.

2
W75R064

4 Remove the differential cross pin tension pin.

5 Remove the differential cross pin.
5 6 Remove two planet wheels.
7 Remove two thrust washers by pivoting them.
7

6
4

6
7

W75R065

Peykan
66 Adjustment and replacement

8 Remove two sun wheels.

9 Remove sun wheels bush.

8
9

W75R066

To assemble
Important:
- Oil the parts as they are fitted.
- Check the condition of the bearing surfaces for
damage or scores. If any are present replace
bearing.
1 - The bearings removed must be replaced by a
new part.
1 Refit bearing using (-).0317D fitting tube.

W75R067

2 Refit the crown wheel, note that the chamfer is

towards the differential unit.
3 Pre-Tighten the eight bolts to 20Nm the fully
tighten the bolts diagonally to 65Nm.
2

3
W75R068

Peykan
 Adjustment and replacement 67

4 Refit the sun wheel bush into the differential

housing and stick with grease.
5 Refit the two sun wheels.

5
4

W75R069

6 Refit two thrust washers to planet wheels.

7 Refit two planet wheels into differential housing.
8 8 Refit cross pin through differential casing and
planet wheels.
9 Secure cross pin with new tension pin.
6

7
9

7
6

W75R070

Peykan
68 Adjustment and replacement

Right-hand drive shaft oil seal

Right-hand oil seal remove
Special tools
1 Ball joint extractor (-).0709.
2 Right-hand output oil seal fitting drift (-).0326E.

1
W75R106

1 Support vehicle in lift and remove front right

wheel.
2 Raise vehicle and remove engine undertray (see
page 20).
3 Drain the gearbox (see page 77).
4 Turn the steering to full left lock and disconnect
right lower suspension arm from the hub carrier
4 using (-).0709 ball joint extractor.

4
W75R107

5 Loosen two intermediate bearing retaining bolt

nuts.
7
6 Rotate retaining bolts 90Þ so offset heads are
clear of bearing outer race.
5 5 7 Pull hub carrier assembly outward, pull inner
driveshaft to free intermediate bearing from
mounting bracket.
8 Remove oil seal protection shield and retain dust
seal off inner end of shaft.
Note: orientation for refit.
9 Support driveshaft to avoid damage.

W75R108

Peykan
 Adjustment and replacement 69

10 Remove oil seal from gearbox.

10

W75R109

To fit
Before refit
- Clean all areas around oil seal aperture and
driveshaft splines.
- Apply grease to oil seal outer lips and driveshaft
inner end splines.
1 Fit new seal into gearbox using (-).0326E fitting
drift.
2 Refit dust shield onto inner shaft, noting position
from remove.
1

W75R110

3 Position inner driveshaft into differential.

4 Refit intermediate bearing into into mounting
4
bracket.
5 Rotate retaining bolts 90Þ so offset heads are
6 6 against bearing outer race.
6 Tighten nuts to 20Nm.

W75R111

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70 Adjustment and replacement

7 Remove oil seal protection shield if fitted as

packing protection on part.

7
W75R112

8 Reconnect right lower suspension arm to the hub

carrier, tighten nut to 250Nm.
9 Refit engine undertray (see page 20)
10 Lower vehicle and refit front right wheel tighten to
85Nm.
11 Refill the gearbox (see page 77).

8
W75R113

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 Adjustment and replacement 71

left-hand drive shaft oil seal

To remove
Special tools
1 Ball joint extractor (-).0709.
2 Left-hand output oil seal fitting drift (-).0326D.

1
W75R193

1 Support vehicle in lift and remove front left wheel.

2 Raise vehicle and remove engine undertray (see
page 20).
3 Drain the gearbox (see page 77).
4 Turn the steering to full right lock and disconnect
left lower suspension arm from the hub carrier
using (-).0709 ball joint extractor.
4

4
W75R114

5 Pull hub carrier assembly outward and withdraw

constant velocity joint from gearbox, support
driveshaft to avoid damage.
6 Remove oil seal from gearbox.

W75R115

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72 Adjustment and replacement

To fit
Before refit
- Clean all areas around oil seal aperture and
driveshaft splines.
2 - Apply grease to oil seal outer lips and driveshaft
inner end splines.
1 Fit new seal into gearbox using (-).0326E fitting
drift.
2 Position constant velocity joint into differential and
gently push into position.
3 Remove oil seal protection shield.
4 Reconnect right lower suspension arm to the hub
carrier using, tighten nut to 250Nm.

4 W75R116

5 Refit engine undertray (see page 20)

6 Lower vehicle and refit front left wheel tighten to
85Nm.
7 Refill the gearbox (see page 77).

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 Adjustment and replacement 73

Input shaft oil seal

Remove
1 Remove gearbox (see page 19).
2 Remove three bolts from release bearing guide.
3 Remove release bearing guide.
4 Remove shim from bearing guide or gearbox
casing.
5 Remove oil seal from release bearing guide.

5
4
3
2

W75R117

To fit
Before refit
- Clean all relevant parts and check for wear.
- Worn parts must be replaced.
- Grease input shaft splines.
1 Oil and fit new seal into bearing guide using
(-).0317W fitting drift.
2 Refit shim to bearing guide.
3 Position bearing guide and refit three retaining
1 bolts, tighten to 12.5Nm.
2
3 4 Refit gearbox (see page 24).
3

W75R118

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74 Adjustment and replacement

Selector shaft oil seal

To remove
1 Support vehicle in lift and remove front left wheel.
2 Raise vehicle and remove left wheel arch liners.
3 Disconnect link rod from gearbox selector shaft.
4 Remove selector shaft seal from gearbox
housing.

4
W75R119

To fit
Before refit
- Clean all relevant parts and check for wear.
- Worn parts must be replaced.
- Grease new seals outer edge and sealing lip.
1 Refit is a reverse of the removal process.

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 Adjustment and replacement 75

Reverse light switch

To remove
1 Disconnect and remove battery (see book 11).
2 Remove battery tray (see book 11).
3 Disconnect reverse light switch multiplug.
4 Remove reverse light switch and washer from
gearbox casing.

3
4

W75R120

To fit
1 Refit is a reverse of the removal process
Note: Discard old washer, refit new.

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76 Adjustment and replacement

Speedometer drive overhaul

To remove
1 Support vehicle on lift and raise.
2 Remove heat shield.
3 Remove the retaining pin.
4 4 Withdraw drive cable.
5 Unplug electrical connector.
6 Remove bolt and washer.

2 6

W75R121

7 Remove speedometer drive.

8 Remove ‘O’ ring
9 Remove pinion.
7 10 Remove oil seal.

8
10

9
W75R122

Note: If the pinion is badly damaged examine the drive

pinion un the gearbox housing.
12 11 Remove right-hand driveshaft (see page 103).
12 Remove three bolts, drive housing to gearbox.
13 Remove drive housing.
14 Remove ‘O’ ring.
15 Remove drive pinion and any adjustment shims.

To fit
Before refit
15
14 - Clean all relevant parts and check for wear.
- Worn parts must be replaced.
13 - Grease new seals outer edge and sealing lip.
- Fit new ‘O’ rings
W75R123 1 Refit is a reverse of the removal procedure.

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 Adjustment and replacement 77

Draining/refilling
Draining
This process can be achieved more efficiently if
gearbox oil is at operating temperature.
Warning: Gearbox oil at operating temperature is
extremely hot so care should be taken against scolding.
1 Raise the vehicle.
2 Remove engine undertray (see page 20).
3 Remove left hand lower wheel arch liner
(see page 21).
4 4 Wipe area clean and remove filler/level plug,
retain sealing washer.
5 Remove drain plug and allow oil to drain
completely into appropriate receptacle.
6 Thoroughly clean, filler/level plug and thread in
gearbox casing.
W75R071

Refilling
Refill gearbox with exact amount of the specified type
of oil (see page 18).
1 Refit drain plug, tighten to 35Nm.
2 Refill oil through gearbox fill/level plug casing
hole. If the correct amount was poured into the
gearbox and a large amount flows out when
checking the level, refit filler/level plug and take
the car on a small journey to distribute the oil
around the gearbox components.
4 3 Check the level, top up accordingly.
4 Fit new washer and refit Filler/level plug to 30Nm.
5 Refit left hand lower wheel arch liner.
6 Refit engine undertray.
W75R072

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 79

Clutch

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 Technical data 81

Technical data
Pressure plate
Type: Diaphragm spring type
Diameter: 200mm

W75S003

Driven plate
Type: Single dry plate with diaphragm spring.

W75S004

Torque wrench settings

Pressure plate retaining bolts: 25Nm

W75S005

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 Special tools 83

Special tools
Plate centralising mandrel
(-).0213

T(-).0213

Peykan
 Technical description 85

Technical description
System overview

W75D009

Power is transmitted from the engine to the gearbox via bearing presses on the “fingers” of the diaphragm,
a clutch. This clutch consists of a dry plate and a these function as levers and release the clamping force
pressure plate of diaphragm spring type. The release of the pressure plate from the driven plate and flywheel.
mechanism is mechanical, being operated by a cable. This disengages the engine from the gearbox.
Power is transmitted from the flywheel on the engine to
the input shaft in the gearbox via a driven plate. This
power is transmitted by the pressure plate, which is
bolted to the flywheel, forcing the friction surface of the
driven plate against the flywheel.
The diaphragm spring on the plate is linked to the input
shaft by a splined connection. When the release

Peykan
 Adjustment and replacement 87

Adjustment and replacement

Clutch overhaul
To remove
1 Remove gearbox (see page 19).
2 Mark the position of the pressure plate assembly
to the flywheel.
6
5 3 Loosen pressure plate bolts working alternatively,
until sprung pressure is released.
4 Remove pressure plate bolts.
5 Remove pressure plates from locating dowels.
6 Remove driven plate.

3,4
W75R127

To Fit
Before fit
- Clean all relevant parts and check for wear.
1 - Replace any worn parts.
1 Place driven plate and pressure plate assembly
on the flywheel at positions marked on remove
and loosely fit bolts.
2 Centre the plate and diaphragm using (-).0213
mandrel.
3 Tighten Pressure plate assembly bolts
alternatively to 25Nm.
3 4 Lubricate gearbox input shaft splines and thrust
bearing guide sleeve.
5 Refit gearbox (see page 24).
2
W75R128

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88 Adjustment and replacement

Clutch release mechanism

To remove
1 Remove gearbox (see page 19).
2 Unhook release bearing from fork and remove
from input shaft.

W75R129

3 Remove roll pin from release lever and remove

3 lever from release shaft using (-).0317V and
(-).0316A.
4 Press retaining tabs and remove upper release
shaft bush from casing.
5 Disengage release shaft from lower bush and
4 remove from casing.
6 Press retaining tabs and remove lower release
shaft bush from casing.

W75R130

To fit
Before refit
- Clean all relevant parts and check for wear.
- Worn parts must be replaced..
1 Refit is a reverse of the removal process.
Note: Always replace release bearing and release lever
roll pin with new parts.

Peykan
 Adjustment and replacement 89

Clutch cable
To remove
1 Disconnect and remove battery and battery fixing
tray (see book 11).
2 Release the inner cable from the clutch gearbox
2 mounting bracket.
3 Release the outer cable from clutch release lever.

W75R131

Working in footwell inside car.

4 Remove three taping screws.
5 Remove right hand fascia lower panel.

4
W75R132

6 Depress the end of the retaining clip and remove

clutch cable.

W75R133

Peykan
90 Adjustment and replacement

7 Free the bellows where the cable runs from the

engine bay through the bulkhead.
8 Pull the cable through the bulkhead.

8
W75R134

9 Release cable from lower wheel arch liner fixing.

10 10 Release cable from clip to air conditioning pipe.
11 Remove cable from vehicle.

W75R135

To fit
Before refit:
- Turn bellows inside out.
- Grease cable end fixings.
1 Pass the cable through the bulkhead and from
3 inside vehicle lock cable end to plastic link.
2 Engage outer cable bushing into the pedal
bracket.
2 3 Push the outer cable stop firmly so it locks into
the bushing.
4 Refit right-hand fascia lower panel.

W75R136

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 Adjustment and replacement 91

5 Fold back bellows over the clutch cable fixing in

the bulkhead.

W75R137

6 Refit the outer cable to clutch release lever.

7 Refit the inner cable to the clutch gearbox
mounting bracket.

W75R138

8 Refit cable to clip on air conditioning pipe.

8 9 Refit cable to lower wheel arch liner.
10 Refit battery fixing tray.
11 Refit and connect battery.

W75R139

Peykan
92 Adjustment and replacement

Clutch pedal
To remove
The clutch pedal is part of an assembly incorporating
the brake pedal and servo. (see book 7 for removal).

W75R140

Peykan
 93

Drive shafts

Peykan
 Technical data 95

Technical data
Torque settings

2 2

3
W75S006

1 Driveshaft nut. 325 Nm.

2 Right hand intermediate bearing retaining bolt nuts. 15 Nm
3 Suspension lower arm ball joint nut. 30 Nm
4 Anti-roll bar drop link-to-lower arm bolt. 75 Nm

Peykan
 Special tools 97

Special tools
Differential seal mounting plug
(-).0317 G

T(-).0317G

Differential seal mounting plug

(-).0317 S

T(-).0317S

AY hub clamp
(-).0606 AY

T.(-).060AY

Peykan
98 Special tools

Ball joint extractor.

(-).0903 AF

T.(-).0903AF

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 Technical description 99

Technical description
System overview

W75D010

Power is transmitted from the gearbox to the wheels by

means of two solid-steel driveshafts of unequal length.
Constant velocity joints are fitted to each end of the
driveshafts, to ensure a smooth and efficient transfer of
power at all suspension and steering angles.

Peykan
100 Technical description

Drive shafts

W75D011

Both driveshafts are splined at their outer ends to

accept the wheel hubs, and are threaded so that each
hub can be fastened by a large nut. The inner end of
each driveshaft is splined, to accept the differential sun
gear.
A very rigid intermediate shaft runs from the right side
of the differential and is mounted in an extra support
bearing attached to the engine block.

Peykan
 Technical description 101

Constant velocity joints

W75D012

The inner constant velocity (CV) joint is of tripod type The outer CV joint transmits engine torque from the
and consists of housing and tripod. The tripod has three drive shaft to hub and wheel. The drive shaft is linked
rollers mounted in needle bearings and can be moved to the outer CV joint with splines and is secured with a
axially in the tripod housing. circlip. The joint is shaped like a bell with spherical
grooves where ball bearings transfer the drive from the
drive shaft to the hub.The CV joint is permanently
greased and protected by a gaiter. the joint is only
lubricated when the gaiter is changed or when the joint
is dismantled for some other reason.

Peykan
 Adjustment and replacement 103

Adjustment and replacement

Driveshaft remove
To remove
Special tools
1 (-).0317 G&S Mounting plugs for differential
2 housing.
2 (-).0606 AY Hub clamp.
3 (-).0709 Ball joint extractor.

1 1

3 W75R141

1 With the vehicle standing on its wheels remove

bolt securing anti-roll bar drop link to lower
suspension arm.
2 Support vehicle on lift and raise.
3 Remove appropriate front wheel.
4 Remove engine undertray (see page 20).
5 Drain gearbox (see page 77).

W75R142

Peykan
104 Adjustment and replacement

6 Remove ‘R’ clip and locking cap.

7 Using hub immobilising tool (-)060AY remove
driveshaft nut.
6 Note:Never apply brakes in order to loosen this nut as
damage may occur to the brake disc retaining bolts.

7 6
W75R143

8 Remove nut from ball joint and use balljoint

extractor (-).0709 to remove lower suspension
arm.

8
W75R144

Left-hand driveshaft
9 Turn the steering to full right lock.
10 Gently pull the left hub carrier to disengage it from
the drive shaft.
11 Remove driveshaft from differential.
Warning: Never move the vehicle with the drive shafts
removed, as this would damage the hub bearings.

11
10
W75R145

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 Adjustment and replacement 105

Right-hand driveshaft
12 Turn the steering to full left lock.
15
13 Loosen two intermediate bearing retaining bolt
13
nuts.
13 14 Rotate retaining bolts 90Þ so offset heads are
clear of bearing outer race.
15 Pull hub carrier assembly outward, pull inner
driveshaft to free intermediate bearing from
mounting bracket.
16 Retain dust seal off inner end of shaft. Note:
orientation for refit.
17 Remove drive shaft through intermediate bearing
mounting bracket.

W75R146

Peykan
106 Adjustment and replacement

To fit
Before refit
- Clean all driveshaft splines and check for wear.
- Worn parts must be replaced.
- Grease new seals outer edge and sealing lips and
driveshaft splines.
- Check all gaiter clips are securely fastened
- Check condition of the left-hand driveshaft seal in
the differential, if worn then replace (see page 71).

Left-hand driveshaft
1 Position inner constant velocity joint into
2 differential and gently push into position
2 Position outer constant velocity joint into steering
hub and gently push hub into position.
3 Refit nut from ball joint to lower suspension arm
and tighten to 45Nm?.

W75R147

4 Using hub immobilising tool (-)060AY refit

driveshaft nut tighten to 265Nm.
5 Refit ‘R’ clip and locking cap.
4

4 5
W75R148

Peykan
 Adjustment and replacement 107

6 Lower vehicle and refit front left wheel tighten to

85Nm.
7 With the vehicle standing on its wheels refit bolt
securing anti-roll bar drop link to lower suspension
arm.
8 Refit engine undertray (see page 20)
9 Refill the gearbox (see page 77).

W75R149

Right-hand driveshaft
10 Refit dust shield onto inner shaft, noting position
12 from remove.
14
3 11 Position inner driveshaft into differential.
14 12 Refit intermediate bearing into into mounting
bracket.
13 Rotate retaining bolts 90Þ so offset heads are
against bearing outer race.
14 Tighten nuts to 20Nm.

W75R150

15 Position outer constant velocity joint into steering

hub and gently push hub into position.
15 16 Refit nut from ball joint to lower suspension arm
and tighten to 45Nm.
17 See steps 4 to 9 left-hand driveshaft.

16

W75R151

Peykan
108 Adjustment and replacement

Rubber gaiter replace

Outer joint
1 Remove appropriate driveshaft as described in
previous section.
3 2 Secure driveshaft firmly in a vice with soft jaws
and release two retaining clips from gaiter.
3 Slide gaiter away from joint.
4 Strike sharply the inner part of the outer joint
using suitable hammer and drift. The joint is held
2 to the driveshaft by a circlip, striking the joint
releases the circlip from its fixing groove.
5 Remove circlip from the driveshaft.
6 Remove the gaiter from the driveshaft and
2 remove gaiter inner end plastic bush.

W75R152

6 Before refit clean all components and inspect if

faults are found then renew joint assembly:
- Ball bearings for cracks, flat spots and surface
pitting.
8 - Ball tracks on inner and outer joints for wear.
7
- Ball cage windows for cracks.
7 Fit plastic rings to new gaiter.
8 Position new plastic bush into recess on drive and
seat gaiter onto bush. Lift lip on gaiter inner end
to release air pressure.

W75R153

9 Fit new circlip onto driveshaft.

10 Refit driveshaft splines into joint and pack the joint
with grease.
11 Refit the gaiter outer lip into recess on joint.
12 Refit two retaining clips.

W75R154

Peykan
 Adjustment and replacement 109

Inner joint
1 Remove appropriate driveshaft as described in
3 previous section.
2 Remove outer constant velocity joint and gaiter as
described opposite.
1 3 Release two retaining clips from gaiter, remove
2 the gaiter from the driveshaft and remove gaiter
inner end plastic bush.
4 4 Remove inner joint from driveshaft.

W75R155

6 Before refit clean all components and check tripod

joint and outer member for wear if faults are found
then renew driveshaft:
8 Position new plastic bush into recess on drive and
seat gaiter onto bush.
9 Pack outer member with grease and position onto
driveshaft.
10 Refit gaiter to recess on outer member and push
member onto the joint, so that its spring-loaded
plunger is compressed. Lift lip on gaiter inner end
to release air pressure.
12 Refit two retaining clips.
13 Refit outer constant velocity joint, as described in
previous section.

W75R156

Peykan
110 Adjustment and replacement

Intermediate bearing replace

To remove
Special tools
1 long reach bearing puller.
2 Fitting drift (-).0409.
1 2

W75R157

1 Remove right hand drive shaft (see page 103).

2 Remove the collar and intermediate bearing from
the driveshaft inner end using extractor.

2
W75R158

To fit
1 Apply grease to the inner race of the new bearing.
2 Refit intermediate bearing to the driveshaft using
(-).0409 fitting drift and hammer, until it contacts
the constant velocity joint.
2 3
3 Refit the collar with drift until it makes contact with
the bearing.
4 Refit right hand driveshaft.

W75R159

Peykan
 111

Gearchange linkage

Peykan
 Technical data 113

Technical data
Torque settings

3
3

3 2

W75S007

1 Gearchange lever bolt: 15 Nm

2 Gearbox lever bolt: 20 Nm.
3 Selector lever mounting bracket nuts: 17 Nm.

Peykan
 Technical description 115

Technical description
System overview

4
5

1 Gear lever.
2 Gear lever housing.
3 Gear lever ball.
4 Ball race.
5 Selector rod.
6 Gear linkage. 2
W75D013

Transfer of force from the gear lever to the gearbox is

via a linkage which transmits both torsional and shear
forces with the least possible friction to achieve low
shifting force.

Peykan
116 Technical description

Technical description
Operation

W75D014

Gate positions are as shown on the gear lever knob.

In order to engage reverse the gearlever must be
depressed whilst selecting reverse. In the neutral
position, the spring-loading inside the gearbox causes
the gear lever to attempt to maintain an equilibrium
position between 3rd and 4th gears. This is so it is easy
for the driver to find his way around the gear layout and
avoid engaging the wrong gear.

Peykan
 Adjustment and replacement 117

Adjustment and replacement

Gearlever/Gearlever housing
To remove
1 Remove centre console and centre ventilation
ducts (see book 10).
3 2 Remove nut and bolt, gear linkage fork to gear
lever. Access is via holes in the side of the
gearlever housing.
2 3 Remove two screws and floor console fixing
bracket.
5
4 4 Remove four nuts gearlever housing to floor
console and remove gearlever assembly.
4
5 Remove gearlever and plastic bushing from
4 housing.

2
4 W75R160

To fit
1 Refit gearlever and plastic bushing into housing.
2 Replace gearlever assembly, Refit four nuts
3 gearlever housing to floor console tighten to
17Nm.
3 Replace floor console fixing bracket and refit two
screws.
4
1 4 Refit gear linkage fork to gear lever.
2 5 Refit centre ventilation ducts and floor console
(see book 10).
2

4
2 W75R161

Peykan
118 adjustment and replacement

Gear linkage overhaul

To remove
1 Remove centre console and centre ventilation
ducts (see book 10).
2 Remove nut and bolt, gear linkage fork to gear
lever. Access is via holes in the side of the
gearlever housing See previous page.
3 3 In Engine bay remove bolt from gear linkage to
ball and socket assembly.
4 Pull the linkage through its bellows into the
interior of the vehicle.

W75R162

5 Remove cap from bellcrank pivot bolt and remove

bolt.
6 Disconnect gear linkage rods and remove
6 bellcrank, ball and socket assembly.

5
6

W75R163

To fit
Refit is a reverse of the remove procedure, however:
- Inspect all linkage components for wear, replace
where required.
- Apply grease to the bulkhead grommet.
- Tighten bolt gear linkage to ball and socket
assembly to 15Nm.

Peykan
 adjustment and replacement 119

Gear knob and gaiter replace

To remove
1 2
1 Turn the gear knob firmly anti-clockwise until
removed from gearlever,
2 Unfasten clips to floor console and remove gear
lever gaiter.
2 3 Refit is a reverse of the remove procedure.

W75R164

Changing bushes in gearlever joint

To remove
Change bushes when there is play in the joint.
1 Remove the gearlever as described earlier in this
section.
2 Tap out the spacer sleeve using a drift.
3 Remove and change bushes.
4 Fit the spacer sleeve.
5 Refit the gearlever.

3
W75D165

Peykan
 SAMAND Service Manuals

The intellectual property rights pertaining to the technical information in

this document are the sole property of the manufacturer. No parts of this
information mar be reproduced of distributed in any from or by any
means, without the prior written consent of the manufacturer.

This document is strictly confidential and reserved for the in-house use
of the IKCO company network.

IKCO after Sales Services Department

SAMAND building (No. 5)
14KM Karaj highway - Tehran - Iran
Tel: +98 21 48909353
Fax: +98 21 48909360
Http://Iksa.ikco.com/Export