Mahindra 35 Series Service Manual page 196

35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June'08
D. Speed Section - RAIL FITTING
1. Slide rail 3 rd & 4 th
hole (K).
rd
2. Assemble 3 & 4
synchronizer in neutral and lock rail and fork with
roll pin.
3. Drop inter lock pin from top.
4. Slide rail 1 & 2 from rear side in top hole.
5. Assemble 1 & 2 fork keeping synchronizer in
neutral and lock fork and rail with roll pin.
6. Insert detent ball, spring, copper washer and
retention bolt and torque with specified value.
E. Forward / Reverse Section - RAIL FITTING
1. Insert special tool in clutch housing from inside.
2. Slide rail from front side.
3. Assemble Forward / Reverse fork without ball &
spring and assembly tool outside.
4. Align special tool slot and fork hole, then insert
ball and spring.
5. Rotate special tool to ensure locking of ball and
spring.
6. Slide rail slowly towards rear keeping fork
assembly in position with tool.
7. Lock the rail by special bolt and copper washer.
8. Check centralization of fork by dial gauge shifting
in forward and reverse direction. If required adjust
the centralization putting remaining shims at
countershaft rear end bearing. Keeping dummy
piece of front retainer.
Transmission
from rear side in bottom
th
fork in rail, keeping
E-19