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Section F
111 - 2
Inspection
Before assembling the gearbox make sure that a thorough
inspection of all components is carried out. Remember that
although a failed component may be easy to identify, the
cause of that failure may be less easy to trace. It is also
possible that a failed component may have caused damage
to other areas of the gearbox.
1
Carefully remove all traces of gasket compound from
components as follows:
a Front and rear casing mating faces.
b Front casing and torque converter housing mating
faces.
2
Clean t he insid e of t he c asings using a suit ab le
degreasing agent.
3
Carefully inspect all gears, bearing and shafts for signs
of excessive wear or damage. If wear or damage is
evident, components must be renewed.
4
Make sure that all oil way cross drillings in the casings,
shafts and gears are clear and free from debris. Blocked
oil ways are a common cause of bearing failure. Use an
air line to blow through cross drillings.
Note: If failure of the forward/reverse or 4 wheel drive clutch
is suspected see the relevant dismantling and assembly
procedure in this section.
1st/2nd Gear Synchromesh Unit
The 1st/2nd gear synchro unit must be checked for wear
before assembly as follows:
1
Before d ismant ling t he unit b e aw are t hat on re-
assembly, the components must be kept in their original
relationships.
2
Dismantle the unit by removing the cones and rings A1,
A2 and B1, B2. Push off the sleeve C taking care to
retrieve the sets of balls D, poppets E and springs F.
3
Inspect the mating faces of cones and rings. The wear
indicator grooves X must still be visible. As a further
check, locate the cones and rings together (as shown at
Y) and measure the clearance between them using
feeler gauges. The clearance should be between 0.5
and 1.9 mm for both A and B pairs. If either is out side
these limits then the complete synchro unit must be
renewed.
Inspect the teeth on all cones and rings for excessive
4
wear or damage. If wear or damage is evident the unit
must be renewed.
9803/3280
Transmission
Synchro Shuttle Gearbox
Purchased from www.WorkshopManuals.co.uk
Section F
111 - 2
Issue 1
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