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2 0 1 0 Transmission
7.3a Undo the cover retaining bolts.
. .
7.3b
. . .
and lift out the cover and shafts
7 . 3 ~ Output shaft (A), intermediate shaft (B), input shaft (C) and
7.4 Intermediate shaft, thrust washers (A) and wave washer (B)
cover dowels (D)
3 Unscrew the bolts securing the relay box
cover and remove the cover, taking care not
to damage the output shaft seal as the shaft is
pulled through
it.
The
output
shaft,
intermediate shaft and input shaft will come
out with the cover (see illustrations). The
cover is fitted with two dowels; note their
position and remove them for safekeeping if
they are loose. Discard the gasket as a new
one must be fitted on reassembly. Note: On
machines not fitted with a drain plug, position
a tray beneath the case to catch the oil when
the cover is removed.
4 Remove the thrust washer and wave
washer (if fitted) from the intermediate shaft,
then lift out the shaft and remove the inner
thrust washer (see illustration). The large and
small pinions are an integral part of the shaft.
5 Lift out the output shaft. The pinion is a
press fit on the shaft and should not be
removed.
6 The input shaft is a press fit in its bearing;
only remove the shaft if a new one is being
fitted, or if a new bearing or seal is being
fitted. Support the cover on blocks of wood
and drive the shaft out using a soft-faced
mallet on the clutch end. If the shaft is being
reused, fit the clutch centre nut to protect the
threads. The pinion is an integral part of the
shaft.
7.8 Check the pinion teeth (A), splines (B)
and threads (C) for wear and damage
Inspection
7 Remove all traces of old gasket from the
case and cover mating surfaces, taking care
not to nick or gouge the soft aluminium if a
scraper is used. Wash all the components in a
suitable
solvent
and
dry
them
with
compressed air.
8 Check the pinion teeth for cracking,
chipping, pitting and other obvious wear or
damage, then check for signs of scoring or
blueing on the pinions and shafts caused by
overheating due to inadequate lubrication
(see illustration). Replace any damaged
components. Note: The input shaft and
intermediate shaft are supplied as paired
items and are not available individually. The
pinion on the output shaft should be a tight fit;
i f i t is loose, fit a new shaft and pinion
assembly.
9 Inspect the splines and threads on the input
and output shafts (see illustration 7.8).
10 Check the intermediate shaft thrust
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