FSO 1305

Service Manual
Transmission




Contents

Foreword .................................................................4
Designations and specifications ..............................5
Lubrication ...............................................................6
Operations ...............................................................7
Power flow ...............................................................8
Sealing compound application ................................9
Torque specifications .............................................10
Axial clearance adjustment ...................................55
Precautions ........................................................... 11
Trouble shooting....................................................14
Symbols.................................................................15
Shift lever tower assembly
Removal and disassembly ...............................16
Reassembly......................................................19
Transmission
Disassembly .....................................................23
Reassembly......................................................55
Clutch housing
Disassembly .....................................................32
Reassembly......................................................34
Transmission housing
Disassembly .....................................................37
Reassembly......................................................37
Shifiting system
Disassembly .....................................................38
Reassembly......................................................39
Countershaft
Disassembly .....................................................41
Reassembly......................................................42
Output shaft assembly
Disassembly .....................................................43
Assembly..........................................................50
Synchronizers assembly
Dissassembly ...................................................48
Reassembly......................................................49
Input shaft
Disassembly .....................................................54
Reassembly......................................................54

FSO 1305 Service Manual - Issued: Octuber 2002 Page: 3

Foreword

The objective of this manual is to provide detailed information to service and repair the Eaton FSO 1305
transmission. This manual is divided into two parts:

1. Technical information and references;

2. Disassembly and assembly of the transmission.

How to use this manual

To disassembly and assembly the transmission follow the manual in its entirety. However, if the problem involves
only one component, refer to the table of contents for the page numbers showing that component.

Example:
Shifting system:
Instruction for disassembly , page 41
Assembly instruction, page 43

For more detailed information regarding product improvement, repair procedures or any other matter related to
the service, please contact:

Eaton Ltd. - Transmission Division

Planning Quality and Field Service
Rua Clark, 2061 - C.P. 304
13270 - Valinhos - São Paulo - Brazil
Phone: area code 19, phone 881 9590

FSO 1305 Service Manual - Issued: Octuber 2002 Page: 4

Designations and Specifications

Nomenclature:

FSO-1305A
Set of gear ratio

Number of forward speeds

Design level

X 100 = nominal torque capacity in Lb.ft

Overdrive

Synchronized

Fuller

Important:
Every Eaton transmission is identified by model and serial number. This information is stamped on the
transmission identification tag and affixed to the case.

Do not remove or destroy the transmission identification tag.

Specifications:

Model Torque Gear ratio General information

Nm Lb.ft 1a 2a 3a 4a 5a Ré
Oil capacity: 2.2 liters
FSO 1305 A 203 150 4,681 2,442 1,497 1,000 0,805 3,940
Weight: 45 Kg
FSO 1305 B 223 165 4,406 2,442 1,497 1,000 0,805 3,940
Lenght : 634,6 mm
FSO 1305 C 244 180 4,022 2,378 1,458 1,000 0,784 3,836

Notes:
1) The oil capacity is approximate, depending on the inclination of engine and transmission. Always refill the
transmission with proper grade and type of lubricant to the level of the filler plug opening (see Lubrication).

2) The weight does not include the shift lever tower.

3) The length corresponds to the distance between the front face of the case and the center line of the yoke.

FSO 1305 Service Manual - Issued: Octuber 2002 Page: 5

Lubrication

Lubrication
Recommended oils
( Prevaliling ambient temperature ) The proper lubrication procedure is the key to a good and complete
maintenance program. If the oil is not doing its job, or if the oil level is ignored,
all the other possible maintenance procedure will note be enough to keep the
transmission running or to assure long transmission life.
Eaton transmission are designed so that all internal parts operate in a bath of
140 60
oil which is circulated by the motion of gears and shafts. Thus, all parts are
122 50 amply lubricated if these procedures are closely followed:
104 40 1. Keep the oil recommended level by inspecting it regularly;
2. Change oil regularly;
86 30
3. Use the specified oil to environment working range of transmission;
68 20

50 10 A

32 0

14 -10

-4 -20

B -30 -30 Oil change and level Inspection

-22 -40
Periodic transmission oil change eliminates possible bearing failures, rings
-58 -50
wear and seizures, since the products of normal wear ins service (tiny metal
Farenheit Celsius particles) which circulate in the oil are harmful to these parts. On the other
hand, the oil changes chemically due to the repeated heating and cooling
cycles of a transmission in use. The table bellow shows the recommended
A: MIL-L-2105C ( 80W90 ) periods for oil level checks and changes.
B: MIL-L-2105C ( 75W90 )

After the first 3,000 miles Change the oil

until 6,000 miles of use

Highway use Every 6,000 miles of use Check the oil level and
possible leaks

Every 25,000 miles of use Change the oil

Após os primeiros 2.500 km Trocar o óleo

rodados

Off-highway use Every 1,500 miles of use Check the oil level and
possible leaks

Every 9,500 miles of use Change the oil

FSO 1305 Service Manual - Issued: Octuber 2002 Page: 6

Lubrication / Operation

Draining

Drain the transmission while oil is warm. To drain the oil, remover the drain plug at bottom of case. Then, clean
the drain plug before re - installing.

Refilling

Clean the case around the filler plug, remove the plug and refill the transmission to the level of the filler
opening. The quantify of oil necessary to refill the transmission depends on its inclination. Do not refill above the
recommended level. This will cause oil to be forced out of the case through the front bearing cover, the control
cover, the shift lever tower, etc.

Inspection

Every time the oil level is being checked, clean the area around the filler plug and, if necessary, add sufficient oil
to maintain the correct level. Do not add oils of different brands and kinds for they might be incompatible.

Operation
The shift lever pattern for the speeds is as follws

a a a
1 3 5 General information

FSO 1305 transmission have 5 forwards speeds and one reverse and are
shifted following the shift pattern shown above. A shift inhibitor feature
prevents the transmission shifting from 5th to reverse gear.
N
Tips for the driver

R
a
2 4a - Always use the clutch to change the gears. The incorrect use of the clutch
may cause premature failures of the synchronizer assembly.
- Always select a starting gear that will provide sufficient reduction for the
load and terrain.
- Never slam or jerk the shift lever to complete gear engagement.
- Never leave the shift lever in the neutral position while going down hill.

FSO 1305 Service Manual - Issued: Octuber 2002 Page: 7

Power flow

The transmission must efficiently transfer the engine’s power or torque to the vehicle’s rear wheels. It is essential
to know what happens in the transmission during torque transfer in order to detect troubles, or else, when repairs
become necessary.

1. The torque from the engine is transferred to the input shaft.

2. The torque is transferred to the countershaft drive gear.
3. The torque is delivered to all countershaft gears.
4. The torque is transferred to the corresponding engaged output shaft gear. The cross section bellow shows the
3rd speed gear engaged.
5. The internal clutching teeth of engaged output shaft gear transfer torque to output shaft through the
synchronizer assembly.
6. The output shaft transfers torque directly to the drive shaft through rear yoke.

FSO 1305 Service Manual - Issued: Octuber 2002 Page: 8

Sealing Compounds Application

The correct application of sealing compounds is important to assure a suitable assembly and to avoid leakage.

Apply sealling
compound Dow
Corning 780 on
Apply Loctite 515 on contact surface of
contact surface of input transmission case and
shaft bearing cover. front plate.
Gasket
Aplicar Loctite 515 na superfície
de contato da tampa retentora
dianteira.

Apply sealing compound Dow

Corning 780 on contact surface of
extension and transmission.

FSO 1305 Service Manual - Issued: Octuber 2002 Page: 9

Torque Specifications

The correct torque application is important to assure a long transmission life. Use torque wrench to obtain the
recommended torque.

Torque 19 up to 26 Nm (14-19 Torque 19 up to 26 Nm (14-19

Lb.ft). Apply Loctite 262 on Lb.ft). Apply Loctite 262 on
threads. threads.

Torque 10 up to 16 Nm
(7-12 Lb.ft)

Torque 10 up to 16 Nm
Torque 2 up to 7 Nm (7-12 Lb.ft)
(14-19 Lb.ft) Apply Loctite 515 on
contact surfaces.

Torque 19 up to 26 Nm Torque 14 up to 20 Nm
(14-19 Lb.ft) (10-15 Lb.ft)
Apply Loctite 262 on Apply Loctite 515 on
threads. contact surfaces.

Torque 19 up to 26 Nm
Torque 19 up to 26 Nm Torque 14 up to 20 Nm (14-19 Lb.ft)
(14-19 Lb.ft) (10-15 Lb.ft)
Loctite 262

FSO 1305 Service Manual - Issued: Octuber 2002 Page: 10

Torque Specifications / Precautions

Torque and lock compound specifications (not showed on illustrations)

Torque
Aplication Instructions
Nm Lb.ft
Clutch housing 54 - 62 40 - 46

Clutch housing elastic pin 4 - 11 3-8

Retaining cover of output 14 - 20 10 - 15 Apply Loctite 262 on threads

shaft intermediate bearing

Protecting plug of switch 14-20 '10-15

hole

Hole cover of selenoid 4-11 3-8

Clutch housing oil bafle 4-11 3-8

Filler plug 19-26 14-19 Apply Loctite 262 on threads

Precautions during disassembly and assembly

Cleaning and handling

In order to completely clean the parts, put them into a bath of solvent (kerosene, for instance), moving every part
up and down slowly until all the old oil and foreign material have been dissolved.
Caution:
Care must be taken to avoid skin rasher, fire hazards and vapor inhalation when using solvents.

Non sealed bearings

Immerse the bearings in clean solvent. Move them up and down in order to loosen the deposits of particles. Dry
the bearings by means of moisture free compressed air. Repeat the operation until the bearings are thoroughly
clean.

Sealed clean bearings

Sealed bearings must not be washed in a cleaning liquid bath and the side seals must not be removed. This type
of bearing, being self lubricated, does not need cleaning or internal lubrication. The removal of a bearing from its
working place has to be very careful and the cleaning can be made only on the outside by means of a dry lint
free cloth.

FSO 1305 Service Manual - Issued: Octuber 2002 Page: 11

Precautions

Synchronizer assembly

The synchronizer is very sensitive to shocks, especially on the hub. Therefore, avoid any inadequate handling,
drops and / or bumps during disassembly / assembly since this may cause internal locking.

Make sure that the marks on the cup and on the hub faces are aligned because this indicates that:
1. The radial play and backlash were selected according to specification.
2. The three internal shifting plates are in their respective positions.

Cases / covers

Clean interior and exterior of cases, covers, etc, thoroughly. The cast parts may be cleaned in hot alkaline
solution baths (we recommend a 7% soluble degreasing oil solution). The parts are to remain in the bath for the
time it takes to become completely clean. The parts cleaned in alkaline solutions are to be rinsed with clean water
to remove any alkaline trace.

Caution:
Care must be taken to avoid vapor inhalation and skin rashes when using alkaline solutions. Every cleaned part
must be totally dried at once by means of moisture free compressed air, or else, by means of a lint free soft cloth,
not containing any abrasive material such as metal filings, contaminated oil or polishing compounds.

Inspection

A thorough and careful inspection of all the parts is of fundamental importance for the transmission life. The
replacement of the parts showing either wear or fatigue will avoid future expensive and foreseen failures.

Gears, shafts and synchronizer assemblies:

Examine carefully the teeth of all the gears for wear, pitting, chipping and cracks. If the gear teeth show spots
where the case hardening is worn through or cracked, the gear has to be replaced by a new one. Inspect the
shafts by checking if they are not warped or excessively worn or having damaged splines. As to the synchronizer
assemblies, make sure the cup and hub marks are always aligned.

Cases, covers, etc.

Inspect the cases, covers, etc to see if they are completely clean and if the contact surfaces and bearing bores
are free from nicks or burrs. Check carefully all the parts for cracks, excessive wear or for any other condition
that may cause oil leak or subsequent failure.

Needle roller bearings

Inspect carefully every needle roller for wear, pitting or spalled areas determining whether they are suitable for
use. After inspection, dip the needle roller bearings in an oil bath and then them in a lint free cloth or paper, so as
to protect them until they are used in the assembly.

Oil seals and snap rings

Any oil seal, snap ring, etc. damaged during maintenance, should be replaced by a new part. The replacement of
the oil seals and snap rings is more economical when unit is disassembled than premature overhaul to replace
these parts at a future time. An oil leakage through a worn seal may result in failures of other more expensive
components of the transmission. The sealing elements are to be handled carefully, particularly during assembly.
Cuts, scratches or rolled up seal lips decrease the sealing efficiency.

FSO 1305 Service Manual - Issued: Octuber 2002 Page: 12

Precautions

Attention:
The snap ring posses assembling position due to the angle of their openings; the side with shorter opening should
be face upward to facilitate the installation with pliers.

Notes:
· When part replacement is deemed necessary, use only genuine replacement parts to assure an extended
transmission performance and a long life.
· Since the price of a new part usually corresponds to a small fraction of the down time and of the replacement
cost, avoid reusing any doubtful part which may cause repairs and additional costs soon after an initial
maintenance.
· To help in the decision as to reusable or replacement of any transmission part, considerations have to be made
as to the transmission history, vehicle mileage, application, etc.

FSO 1305 Service Manual - Issued: Octuber 2002 Page: 13

Trouble Shooting

List of most probable failures causes

Failure Probable causes

Noise arising in neutral - Incorrect Idling speed;

- Misalignment due to loose screw;
- Lack or low level of lubricant oil;
- Damaged or excessively worn gear teeth;
- Damaged or excessively worn bearing;
- Foreign metallic particles in the lubricating oil;

Noise arising in gear - Misalignment of transmission and engine;

- Gear with irregular contact, excessive play or damages;
- Damaged or excessively worn bearing;
- Lack or low level of lubricant oil;
- Warped output shaft or countershaft;
- Foreign metallic particles in the lubricating oil;
- Incorrect lubricant.

Noise arising outside of transmission - Out of balance fan;

-Defective vibration dampener;
- Out of balance flywheel;
- Out of balance clutch;
- Loose or not effective engine mountings;
- Worn, damaged or incorrectly installed universal joint;
- Out of balance or Warped drive shaft.

Difficult shifting - Improperly operating clutch (does not release properly);

- Non specified or low level lubricating oil;
- Warped or damaged shift lever tower components;
- Irregular selective adjustment of the cup and the hub;
- Worn or warped components of the control cover assembly;
- Incorrect clutch pedal travel adjustment.

Crashing on engagement - Incorrect clutch pedal travel adjustment;

- High idling of the engine;
- Gear or synchronizer with damaged clutch teeth;
- Worn synchronizer rings;
- Low tension on synchronizer springs;
- worn yoke nylon pads.

Sticking in gear - Incorrect clutch pedal travel adjustment;

- Irregular selective adjustment of the cup and the hub;
- Misaligned or warped output shaft;
- Warped, worn or damaged shift bar housing components;
- High tension on actuator spring;
- worn actuator lodgment in the extension.

Jump out of the gear - Misaligned between transmission and engine;

- Worn or damaged gear teeth;
- incomplete engagement;
- Excessive vibration on the shift lever due to engine or
transmission support pads (not effective);
- Excessive axial clearance;
- Dust cover interfering with the shift lever;
- High tension on actuator spring.

Oil leak - Oil lever higher than specified;

- Worn or damaged oil seal;
- Cracked or porous transmission case, covers or bearing
covers;
- Warped contact surfaces;
- Obstructed breather;
- Screws with low torque or without Loctite application.

Needle bearing failure - Lack of initial lubrication on reassembly in unit overhaul;

- Foreign material particles in the lubricant;
- Lack of, low level or incorrect lubricant;
- Improper reassembly in unit overhaul (impact without proper
device).

Engagement of two gear simultaneously - Missing shift rod locking pin or mesh lock balls.

FSO 1305 Service Manual - Issued: Octuber 2002 Page: 14

Symbols/ Dissassembly and
Assembly

Some pattern operations, such as, sealing compound application, torque specifications and tools utilization, are
identified by symbols, to make ease the visualization and understanding.

Tools utilization
The symbol indicates the utilization needing of special tools or, when standard tools are used, the
symbol are followed by the tool size (wrench, socket, pliers, etc).

Example:

Sealing and locking compound application

The symbol indicates operations that need sealing or locking compounds application. The symbol are
followed by the kind of product and by the place where the compound is to be applied.

Torque application
When a operation involves torque application, this condition is indicated by a specific symbol. The
symbol is followed by the torque values, in Nm and Lb.ft . The symbol and torque values are preceding
by the size of socket or wrench used on torque application.

The disassembly and assembly sequences shown are typical of a FSO 1305 transmission. Some pictures show
different parts of each model, according to its application.

Attention:
During transmission assembly, is important to lubricate all gears, needle bearings, rollers, taper roller bearings,
and components under friction with the same oil specified for transmission, to avoid damage initial turns of
gears.

FSO 1305 Service Manual - Issued: Octuber 2002 Page: 15

Direct Shifit Lower Tower

1. Upper shift lever

2. Screw
3. Cover
4. Dust cover
5. Nut
6. Lower shift lever
7. Articulation pin
8. Washer
9. Bushing
10. Threaded plug
11. Spring
12. Plunger
13. Articulation screw
14. Screw
15. Washer
16. Spring
17. Ball
18. Pin
19. Torsion spring
20. Cam
21. Guide pin
22. Gasket
23. Articulation bracket

1. Removal and disassembly

1.1 Positioning shift lever in neutral. Lose the four
screws and washer of shift lever tower assembly.

Socket 11 mm

1.2 Remove the shift tower assembly and gasket of

transmission case.

FSO 1305 Service Manual - Issued: Octuber 2002 Page: 16

Direct shift lower tower

1.3 Positioning the shift lever tower in a vise or suitable

support, with shift lever side section downside. Remove
bushing of lever lower end.

1.4 Invert positioning of shift lever tower and remove the

four screws of upper cover.

Socket 8 mm

1.5 Remove the upper cover and dust cover.

1.6 Lose and remove the lever side screws.

Socket 18 mm

FSO 1305 Service Manual - Issued: October 2002 Page: 17

Direct shift lower tower

1.7 Disengage the lever from tension plugs.

1.8 Remove the lever assembly, pulling it upside.

Remove the two nylon side washers.

1.9 Lose the threaded plugs of plunger tension springs.

Allen wrenche 6 mm

1.10 Remove the threaded plugs and tension springs.

FSO 1305 Service Manual - Issued: October 2002 Page: 18

Direct shift lower tower

1.11 Remove the plungers, pressing them outside.

1.12 Remove the springs and plungers lock balls.

2. Assembly and installation

2.1 Insert the springs and the plungers lock balls.

2.2 Install the lever tension plungers, pressing them into

their lodgments.

FSO 1305 Service Manual - Issued: October 2002 Page: 19

Direct shift lower tower

2.3 After installation, verify the positioning of plungers.

2.4 Install the tension springs and plugs. Apply Loctite

515 on contact.

Loctite 515

2.5 Tighten the retaining nuts of tension plugs to a 14 -

20 Nm (10-15 Lb.ft).

Allen wrenche 14 - 20 Nm
6mm ( 10 - 15 Lb.ft )

2.6 Positioning the shifting lever on the control tower,

inserting in this lodgment, together with side washers.

FSO 1305 Service Manual - Issued: October 2002 Page: 20

Direct shift lower tower

2.7 Align the holes of washers, lever articulation and

tower housing.

2.8 Apply a coat of Loctite 515 on contact surface of

articulation screws and install then, tighten to a 10 - 16
Nm (7-12 Lb.ft).

Loctite 515

Socket 10-16 Nm
35 mm ( 7-12 Lb.ft )

2.9 Install the dust cover and upper cover on shift lever
tower. Apply Loctite 262 on threads of 4 screws and
install them, tighten to a 2 - 7 Nm (2-7 Lb.ft) torque.

Loctite 262

Socket 2-7 Nm
8 mm ( 1-5 Lb.ft )

2.10 Invert positioning of tower assembly and engage

bushing on lower end of lever.

FSO 1305 Service Manual - Issued: October 2002 Page: 21

Direct shift lower tower

2.11 Positioning a new gasket and tower assembly over

extension lodgment, verify the positioning of bushing on
shifting sector.

2.12 Install the four screws of tower assembly, applying

a 19-26 Nm (14-19 Lb.ft).

Loctite 262

Socket 19-26 Nm
11 mm (14-19 Lb.ft )

FSO 1305 Service Manual - Issued: October 2002 Page: 22

Transmission

1. Oil seal 23. Bushing

2. Bushing 24. Snap ring
3. Extension 25. Transmission housing
4. Speedometer sensor 26. Filler plug
5. Reverse light switch 27. Drain plug
6. Washer 28. Oil baffle
7. Adapter plate 29. Screw
8. Washer 30. Bushing
9. Screw 31. Adapter plate
10. Screw 32. Screw
11. O’ring 33. Oil seal
12. Cover 34. Bearing cup
13. Screw 35. Input shaft bearing cover
14. Bushing 36. Screw
15. Plug 37. Stud
16. Output shaft bearing cover 38. Clutch housing
17. Gasket 39. Washer
18. Needle bearing 40. Fulcrum pin
19. Shim 41. Clutch yoke
20. Reverse idle gear axle 42. Clutch releasing bearing
21. Taper rolling bearing cover 43. Washer
22. Guide pin 44. Screw

FSO 1305 Service Manual - Issued: October 2002 Page: 23

Transmission

45. Snap ring 66. Thrust washer 87. Spring ring

46. Ball bearing 67. Snap ring 88. Lamella
47. Snap ring 68. Needle bearing 89. Synchronizer hub
48. Snap ring 69. 1st speed gear 90. Spring ring
49. Speedometer rotor 70. Spacer 91. Synchronizer sleeve
50. Ball 71. Snap ring 92. Snap ring
51. 5th speed gear 72. Inner synchronizer ring 93. Taper roller bearing
52. Synchronizer ring 73. Intermediate synchronizer ring 94. Synchronizer ring
53. Snap ring 74. Outer synchronizer ring 95. Input shaft
54. Spring ring 75. Spring ring 96. Taper roller bearing
55. Lamella 76. Lamella 97. Thrust washer
56. Synchronizer hub 77. Synchronizer hub 98. Rear countershaft
57. Spring ring 78. Spring ring 99. Thrust washer
58. Synchronizer sleeve 79. Synchronizer sleeve 100. Roller bearing
59. Spacer 80. Outer synchronizer ring 101. Countershaft
60. Needle bearing 81. Intermediate synchronizer ring 102. Needle bearing
61. Synchronizer ring 82. Inner synchronizer ring 103. Needle bearing
62. Reverse gear 83. 2nd speed gear 104. Reverse idle gear
63. Snap ring 84. Output shaft 105. Bearing inner ring
64. Thrust washer 85. 3rd speed gear 106. Roller bearing
65. Taper roller bearing 86. Synchronizer ring

FSO 1305 Service Manual - Issued: October 2002 Page: 24

Transmission

1. Disassembly
1.1 Hold the transmission on a suitable device.

Socket 11 mm

1.2 Remove the speed sensor with the O’ring.

Socket 1 polegada

1.3 Remove the reverse light switch.

Socket 22 mm

1.4 Lose the threaded plug of shifting system position

pin.

Socket 21 mm

FSO 1305 Service Manual - Issued: October 2002 Page: 25

Transmission

1.5 Remove the threaded plug, the spring and positioning

pin of their lodgment.

1.6 With 2a or 4th gear engaged, remove the elastic pin

of shift lug.
Note: After disassembling, remove the pin from
transmission inside.

1.7 Lose the screws and remove the adapter plate of

transmission rear bracket.

Socket 13 mm

1.8 Positioning transmission vertically, with extension

upside. Lose the 10 screws with fasten extension to
transmission housing.

Socket 11 mm

FSO 1305 Service Manual - Issued: October 2002 Page: 26

Transmission

1.9 Use two bars to help the sealant cord to be broken

and remove the extension of transmission, together with
shift plug.
Attention: Take care to avoid the rear countershaft rollers
to be lost.

1.10 If necessary, remove the rollers of rear

countershaft.

1.11 Remove the bearing snap ring.

1.12 Remove the sealed bearing.

Special tool

FSO 1305 Service Manual - Issued: October 2002 Page: 27

Transmission

1.13 Remove the two snap rings.

1.14 Remove the speedometer rotor and lock ball.

1.15 Remove the rear countershaft using a device.

Remove the lower washer of countershaft.

Special tool

1.16 Remove the 5th speed gear and the synchronizer

ring.

FSO 1305 Service Manual - Issued: October 2002 Page: 28

Transmission

1.17 Remove the elastic pin of 5th and reverse shift

yoke.

1.18 Remove the snap ring of synchronizer assembly.

1.19 Remove the 5th and reverse synchronizer assembly,

together with shift yoke.

1.20 Remove the reverse gear and synchronizer ring.

FSO 1305 Service Manual - Issued: October 2002 Page: 29

Transmission

1.21 Remove the thrust washer and the reverse gear

needle bearing.

1.22 Remove the reverse idle gear and the two needle
bearings.

1.23 Remove the side pin of shifting space bushing.

Special tool

1.24 Remove the 10 screws with fasten the transmission

housing to adapter plate.

Socket 11 mm

FSO 1305 Service Manual - Issued: October 2002 Page: 30

Transmission

1.25 Open the snap ring of countershaft bearing and, with

two suitable bars, remove the transmission housing.

1.26 Remove simultaneously the output shaft, the

countershaft and shifting yokes.

FSO 1305 Service Manual - Issued: October 2002 Page: 31

Clutch housing

1. Oil baffle 10. Studs

2. Screw 11. Clutch housing
3. Bushing 12. Washer
4. Adapter plate 13. Fulcrum pin
5. Screw 14. Clutch yoke
6. Oil seal 15. Clutch release bearing
7. Bearing cup 16. Washer
8. Input shaft bearing cover 17. Screw
9. Screw

1. Disassembly
1.1 Remove the two screws and remove the oil baffle.

Socket 10 mm

1.2 Tilt the cover to remove the clutch bearing.

FSO 1305 Service Manual - Issued: October 2002 Page: 32

Clutch housing

1.3 Use the screwdriver to disengage the clutch yoke of

fulcrum pin.

1.4 Remove the four screws of input shaft retaining

cover.

Socket 11 mm

1.5 Invert positioning clutch housing and remove input

shaft bearing cover using a device.

Special tool

1.6 Remove the input shaft bearing cup using a device.

Special tool

FSO 1305 Service Manual - Issued: October 2002 Page: 33

Clutch housing

1.7 Remove the countershaft bearing cup using a

device.

Special tool

1.8 Remove the screws that fasten the clutch housing to

adapter plate and separate them.

Socket 19 mm

1.9 If necessary, remove the input shaft bearing cover oil

seal.

2. Assembly
2.1 Positioning the adapter plate on clutch housing and
install the screws, tighten them to a 54 - 62 Nm (40-46
Lb.ft) torque.

Socket 54-62 Nm
19 mm (40-46 Lb.ft )

FSO 1305 Service Manual - Issued: October 2002 Page: 34

Clutch housing

2.2 Install the front bearing of countershaft, using a

device.

Special tool

2.3 Install the input shaft bearing cup with a device.

Special tool

2.4 Install the oil seal of input shaft bearing cover using
a device.

Special tool

2.5 Apply Loctite 515 on contact surface of input shaft

bearing cover. Fix the cover with the 4 screws (threads
covered with Loctite 262), tighten them to a 19 - 26 Nm
(14-19 Lb.ft) torque.

Socket 19-26 Nm
11 mm (14-19 Lb.ft )

Loctite 262

FSO 1305 Service Manual - Issued: October 2002 Page: 35

Clutch housing

2.6 Engage the clutch yoke on fulcrum pin; tilt the yoke
to install the clutch release bearing.

2.7 Install the oil baffle and fix it with two screws (threads
covered with Loctite 262), applying a 4 - 11 Nm (3-8
Lb.ft) torque.

Socket 4-11 Nm
11 mm (3-8 Lb.ft )

FSO 1305 Service Manual - Issued: October 2002 Page: 36

Transmission Housing

1. Output shaft bearing cover 6. Guide pin

2. Screw 7. Bushing
3. Shim 8. Retaining ring
4. Reverse idle gear axle 9. Transmission housing
5. Taper roller bearing cup 10. Filler plug
11. Drain plug

1. Disassembly
1.1 Remove the 4 allen screws of output shaft rear
bearing retaining cup; remove the shims.

2. Assembly
2.1 Reinstall the original pack of shims and the rear
bearing retaining cup.

Loctite 262

Allen wrenche 14-20 Nm

5 mm (10-15 Lb.ft )

FSO 1305 Service Manual - Issued: October 2002 Page: 37

Shifting System

1. Shifting lug 10. Bushing

2. Elastic pin 11. Nylon pad
3. Elastic pin 12. Plug
4. 1st and 2nd shift yoke 13. Spring
5. Bushing 14. Plunger
6. Nylon pad 15. Shifting rod
7. Inner shift bushing 16. 5th and reverse shifting rod
8. Outer shift bushing 17. 5th and reverse shifting yoke
9. 3rd and 4th shift yoke 18. Nylon pad

1. Disassembly
1.1 Align the inner and outer bushings with 1st and 2nd
yoke rod.

1.2 Hold the outer bushing together with 3rd and 4th
yoke with the 5th and reverse shifting rod; pull the
shifting rod together with f1st and 2nd shift yoke.

FSO 1305 Service Manual - Issued: October 2002 Page: 38

Shifting System

1.3 If necessary, remove the elastic pin of inner bushing

and remove it of shifting rod.

1.4 Remove the Nylon pad.

2. Assembly
2.1 Install the Nylon pad.

2.2 Positioning the inner bushing on shifting rod and

hold it with the elastic pin. Certify that the bushing tab
are positioning at same side of rod channels.

FSO 1305 Service Manual - Issued: October 2002 Page: 39

Shifting System

2.3 Insert the 5th and reverse rod on 1st and 2nd shift
yoke with inner bushing installed.

2.4 Positioning the 3rd and 4th yoke and outer bushing,
observing that the slot of bushing are facing downside.

2.5 Engage the subassemblies mounted on items 2.3

and 2.4, verifying the alignment of tabs and channels.

2.6 After assembly, verify the correct alignment of

components.

FSO 1305 Service Manual - Issued: October 2002 Page: 40

Countershaft

1. Thrust washer 6. Needle bearing

2. Rear countershaft 7. Needle bearing
3. Thrust washer 8. Reverse idle gear
4. Roller bearing 9. Bearing inner ring
5. Countershaft 10. Roller bearing

1. Disassembly
1.1 Remove the front bearing inner ring of countershaft
using a device.

Special tool

1.2 Remove the rear roller bearing of countershaft using

a device.

Special tool

FSO 1305 Service Manual - Issued: October 2002 Page: 41

Countershaft

2. Assembly
2.1 Lubricate and install the rear roller bearing.

Special tool

2.2 Install the inner ring of front bearing of countershaft.

Special tool

FSO 1305 Service Manual - Issued: October 2002 Page: 42

Output Shaft

1. Snap ring 18. Synchronizer ring 35. Spring ring

2. Ball bearing 19. Reverse gear 36. Synchronizer sleeve
3. Snap ring 20. Snap ring 37. Outer synchronizer ring
4. Snap ring 21. Thrust washer 38. Intermediate synchronizer ring
5. Speedometer rotor 22. Taper roller bearing 39. Inner synchronizer ring
6. Ball 23. Thrust washer 40. 2nd speed gear
7. 5th speed gear 24. Snap ring 41. Output shaft
8. Synchronizer ring 25. Needle bearing 42. 3rd speed gear
9. Snap ring 26. 1st speed gear 43. Synchronizer ring
10. Spring ring 27. Spacer 44. Spring ring
11. Lamella 28. Snap ring 45. Lamella
12. Synchronizer hub 29. Inner synchronizer ring 46. Synchronizer hub
13. Spring ring 30. Intermediate synchronizer ring 47. Spring ring
14. Synchronizer sleeve 31. Outer synchronizer ring 48. Synchronizer sleeve
15. 32. Spring ring 49. Snap ring
16. Spacer 33. Lamella 50. Taper roller bearing
17. Needle bearing 34. Synchronizer hub

1. Disassembly
1.1 Secure the output shaft for disassembly, in manner
their components won’t be damaged.

FSO 1305 Service Manual - Issued: October 2002 Page: 43

Output Shaft

1.2 Remove the taper roller bearing using a device.

Special tool

1.3 Remove the snap ring and the 3rd and 4th
synchronizer assembly.

1.4 Remove the synchronizer ring and the 3rd speed

gear.

1.5 Secure the output shaft at other extremity, in manner

their components won’t be damaged.

FSO 1305 Service Manual - Issued: October 2002 Page: 44

Output Shaft

1.6 Remove the snap ring and the washer of taper roller
bearing.

1.7 Remove the 1st speed gear with bearing and washer
using a device.

Special tool

1.8 Remove the taper roller bearing, the thrust washer

and the 1st speed gear.

1.9 Remove the tricone assembly of 1st and 2nd speed

synchronizer (inner, intermediate and outer rings).

FSO 1305 Service Manual - Issued: October 2002 Page: 45

Output Shaft

1.10 Remove the snap ring of 1st speed gear needle

bearing.

1.11 Remove the needle bearing and spacer.

1.12 Remove the snap ring and the 1st and 2nd
synchronizer assembly.

1.13 Remove the tricone assembly (inner, intermediate

and outer rings).

FSO 1305 Service Manual - Issued: October 2002 Page: 46

Output Shaft

1.14 Remove the 2nd speed gear.

FSO 1305 Service Manual - Issued: October 2002 Page: 47

Synchronizers

1. Spring ring 3. Synchronizer sleeve

2. Synchronizer hub 4. Lamella

1. Disassembly
1.1 Verify the positioning marks between hub and sleeve
to keep the same positioning during assembling.

1.2 Remove spring rings of lamellas, on both sides.

1.3 Remove the lamellas.

FSO 1305 Service Manual - Issued: October 2002 Page: 48

Synchronizers

1.4 Remove the synchronizer hub from sleeve.

2. Assembly
2.1 Install the synchronizer hub on sleeve, observing the
alignment marks.

2.2 Install the lamellas, observing their correct positioning

on slots.

2.3 Install the spring rings of lamellas, on both sides.

Attention: The two bent ends of the spring are to be
housed between the lamellas and the opposite vertical
slot.

FSO 1305 Service Manual - Issued: October 2002 Page: 49

Output Shaft

2. Assembly
2.1 Secure the output shaft in a vise, using aluminum
protection on the jaws.

2.2 Lubricate and install the 2nd speed gear.

2.3 Install the tricone synchronizer assembly of 2nd

speed (inner, intermediate and outer ring).

2.4 Install the 1st and 2nd synchronizer assembly and

the snap ring.
Attention: Verify if synchronizer assembly is correct
placed.

FSO 1305 Service Manual - Issued: October 2002 Page: 50

Output Shaft

2.5 Install the spacer and the needle bearing of 1st

speed gear.

2.6 Fix the needle bearing with the snap ring.

2.7 Install the tricone synchronizer assembly of 1st

speed (inner, intermediate and outer ring).

2.8 Install the 1st speed gear, the thrust washer and the
taper roller bearing.

FSO 1305 Service Manual - Issued: October 2002 Page: 51

Output Shaft

2.9 Install the taper roller bearing using a device.

Special tool

2.10 Install the thrust washer and the snap ring of taper
roller bearing.

2.11 Secure the output shaft at the opposite extremity in

a vise, using aluminum protector on the jaws.

2.12 Lubricate and install the 3rd speed gear and the
synchronizer ring.

FSO 1305 Service Manual - Issued: October 2002 Page: 52

Output Shaft

2.13 Install the 3rd and 4th speed synchronizer assembly

and the snap ring.
Attention: Verify the correct positioning of synchronizer
assembly.

2.14 Install the taper roller bearing, using a device.

Special tool

FSO 1305 Service Manual - Issued: October 2002 Page: 53

Input Shaft

1. Synchronizer ring
2. Input Shaft
3. Taper roller bearing

1. Disassembly
1.1 Remove the taper roller bearing, using a device.

Special tool

2. Assembly
2.1 Install the taper roller bearing, using a device.

Special tool

FSO 1305 Service Manual - Issued: October 2002 Page: 54

Axial Clearance

The output shaft work with a determined axial clearance. The

clearance is 0.025 up to 0,100 mm ( 0.001 up to 0.004 inches).

The axial clearance of output shaft is adjusted by a package of

shims, positioned under the input shaft intermediate bearing cover.

When transmission is disassembled, the axial clearance of output

shaft should be measured and recorded. If obtained values are
under specifications, use the original package of adjusting shims
during assembly.

When the transmission is assembled, the axial clearance of output

shaft should be measured again. If incorrect values of axial
clearance are obtained at this time, the input shaft bearing cover
should be removed, and the thickness of shim package should be
changed as follow:

· To increase clearance, increase the total thickness of shim

package.

· To decrease clearance, decrease the total thickness of shim package.

2. Assembly
2.1 Secure the clutch housing on a assembly device.

2.2 Positioning the output shaft, countershaft, shifting

system and input shaft to allow them to be placed
simultaneously over clutch housing.

FSO 1305 Service Manual - Issued: October 2002 Page: 55

Transmission

2.3 Apply sealing compound (Dow Corning 780) on

the contact surface of clutch housing with transmission
housing.

Down Corning 780

2.4 Install the transmission housing over assembly

mounted on item 2.2, observing the alignment of guide
pins of transmission with holes of clutch housing.

2.5 Open the retaining ring of countershaft bearing, to

allow it to engage in its lodgment and the final positioning
of transmission housing.

2.6 Install the side pin which locks the selector sleeve in
this position.

FSO 1305 Service Manual - Issued: October 2002 Page: 56

Transmission

2.7 Apply Loctite 262 on threads of housing screws and

install them, tighten to a 19 up to 26 Nm ( 14 up to 19
Lb.ft).

Loctite 262

Socket 19-26 Nm
11mm (14-19 Lb.ft )

2.8 Verify the axial clearance of output shaft assembly,

using a device. The specified value is 0.025 up to
0.100 mm (0.001 up to 0.004 inches). If value is out of
specification, remove the output shaft bearing retainer
cover and shims. Add or remove shims to keep the
clearance into specified range. Install the selected shims,
the output shaft bearing cover and the screws. Tighten
the screws to 14 up to 20 Nm (10 up to 15 Lb.ft).

2.9 Install the thrust washer of 5th speed countershaft.

2.10 Install the needle bearing and the reverse idle

gear.

FSO 1305 Service Manual - Issued: October 2002 Page: 57

Transmission

2.11 Install the needle bearing and spacer.

2.12 Install the reverse gear and synchronizer ring.

2.13 Install the 5th and reverse synchronizer with the

yoke.
Attention: Verify the engagement of synchronizer rings
slots with lamellas.

2.14 Install the elastic pin of yoke.

FSO 1305 Service Manual - Issued: October 2002 Page: 58

Transmission

2.15 Lubricate and install the 5th speed gear with the
synchronizer ring.

2.16 Install the rear countershaft.

2.17 Install the lock ball and the speedometer rotor,

observing the correct alignment.

2.18 Install the speedometer rotor snap ring.

FSO 1305 Service Manual - Issued: October 2002 Page: 59

Transmission

2.19 Install the output shaft rear bearing, using a

device.

Special tool

2.20 Install the snap ting of output shaft rear bearing.

2.21 Insert the shift lug on selector rod verifying the

correct positioning. Turn the shift lug around shaft to
allow the extension to be installed.

2.22 Install the rollers on their lodgment on extension.

Use grease hold rollers in position.

FSO 1305 Service Manual - Issued: October 2002 Page: 60

Transmission

2.23 Prepare the extension applying a coat of sealing

compound (Down corning 780) on contact surface with
housing. Hold the thrust washer of rear countershaft with
grease. Observing the correct positioning. Apply a coat
of grease on oils seal lip and extension bushing.

Down Corning 780

2.24 Install the extension over transmission housing,

avoiding drop of rollers or rear countershaft thrust
washer. Verify the correct alignment with shift lug.

2.25 Apply Loctite 262 on threads of extension screws.

Install the screws, tighten to 19 up to 26 Nm torque
(19-26 Lb.ft).

Loctite 262

Socket 19-26 Nm
11mm (14-19 Lb.ft)

2.26 Positioning the adapter plate of rear bracket of

transmission and install the two screws. Tighten to 19 up
to 26 Nm torque (14-19 Lb.ft).

Socket 19-26 Nm
11mm (14-19 Lb.ft)

FSO 1305 Service Manual - Issued: October 2002 Page: 61

Transmission

2.27 Positioning shift lug on shaft, to align their holes; fix

the shift lug with the elastic pin.

2.28 Apply a coat of grease on extremity of shift

positioner plunger. Install the plunger, the spring and the
threaded plug.

2.29 Apply Loctite 515 on contact surface of threaded

plug and tighten it to a 14 up to 20 Nm torque (10-15
Lb.ft).

Loctite 515

Socket 14-20 Nm
21mm (10-15 Lb.ft)

2.30 Install the back lamp switch and tighten it to a 14 up

to 20 Nm torque (10-15 Lb.ft).

Socket 14-20 Nm
21mm (10-15 Lb.ft)

FSO 1305 Service Manual - Issued: October 2002 Page: 62

Transmission

2.31 Install the magnetic sensor of speedometer, verifying

the correct positioning of O’ring.

2.32 Tighten the magnetic sensor to a 10 up to 16 Nm

torque (7-12 Lb.ft).

Soquete 1 10-16 Nm
polegada (7-12 Lb.ft)

FSO 1305 Service Manual - Issued: October 2002 Page: 63

FSO 1305 Service Manual - Issued: October 2002 Page: 64