Tata Indigo gearbox disassembly

Preamble

It is stunning to see that, virtually, all the internet do not have instructions (or, more precisely, clear/complete instructions) on how to disassemble a gearbox for Tata Indigo (as well Marina, Indica); one can however, buy a workshop manual for Rover Cityrover, a same car with different branding (I was terribly lucky to even find that manual). Here, complete know how for the procedure is provided for free, step by step; wanna get it how? Let's go!!!

Important! It is assumed that the gearbox has already been taken out of the car; this procedure needs another chapter!

Step 1 of 10: Remove a reverse gear light switch

Step 2 of 10: Remove the gearbox top cover, remove 3 12mm bolts

Step 3.1 of 10: Remove the nuts from the top of the output and input shafts and then the roll pin securing the 5th gear shift fork to the shift shaft; pull off the shift fork TOGETHER WITH 5th gear sleeve, top washer and driven gear

Step 3.2 of 10: Tip! It may be worthy to note the orientation of the washer on top of the driven 5th gear assembly

Step 4 of 10: Pull off the remainder of the 5th gear assembly from the output shaft; in this case the synchronizer and the (5th) driving gear. You may need to use a flat screw driver at the bottom of the driving gear to push out the components

Step 5 of 10: Pull off the 5th driving gear from the input shaft

Step 6 of 10: Pull off the washer from the output shaft (note it's orientation!! the depressions on either side of it points upwards!!)

Step 7 of 10: Remove a set of hex screws from semi-circular clips around both, the input and output shaft collars and then (using a flat head screwdriver) pull off the clips

Step 8.1 of 10: By the side of the gearbox there is a small flat cover with two bolts; remove the bolts and the cover, take out three springs from the three holes under the cover (note that one spring is shorter and stronger than the rest; it should be returned to the same hole it came from!!) and CAREFULLY tilt the gearbox to remove the three ball bearings from the holes

Step 8.2 of 10: Important! Once again it emphasized that one spring is shorter and stronger; it should be returned to the hole it came from!

Step 9.1 of 10: Remove all the bolts around the gearbox housing. Some of the gearbox housing bolts (like the one shown) have small brackets; note them so that, during re-assembly, they are returned back to the same locations

Step 9.2 of 10: Important! Two of the gearbox housing bolts are longer than the rest; make sure they are noted and, during re-assembly, they are returned to the same locations

Step 10 of 10: Using a fairly sharp flat head screw driver, pry around the junction between the gearbox housing and the base and pull off the gearbox housing; the inside of the gearbox will now be fully exposed for troubleshooting, repair, etc.

I hope that was helpful! Kindly donate through a PayPal account eliasjl2019@gmail.com for sustainability; even a dollar will be highly appreciated!

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