Reliant Rebel 700 1967 Workshop Manual page 44

st nd
12. Turn the 1 /2 fork lever through 180° and remove the
5/16"UNF cone screw.
13. Using a suitable drift, remove the shaft by tapping it in to
the bell housing, taking care not to lose the interlock pin.
14. Remove the selector forks. Note that the 1
shorter boss than the 3
15. Using a suitable drift, tap the layshaft into the bell housing.
This will allow the laygear to drop in to the gearbox casing
allowing the removal of the primary gear.
16. Remove the mainshaft cluster by withdrawing it through
the rear aperture of the gearbox.
17. Using a drift through the mainshaft aperture bearing on to
the bottom of the primary gear, gently tap the main shaft in
to the bell housing complete with the primary bearing.
18. Remove the laygear and the laygear thrust washers.
19. Remove 7/16"UNF screw and lock washer and carefully tap
the reverse idler gear shaft to the rear of the gearbox. Note
there should be no need to remove the reverse lever. If this
is necessary remove the pivot pin.
Reassembling the gearbox
Reverse gear assembly
1. Fit reverse lever bush, lock washer and reverse lever to the
gearbox and secure with the pivot pin and ¼"UNF hexagon
nut. Note It is important to ensure that the chamfered side
of the reverse lever faces towards the front of the gearbox.
2. Fit new reverse gear bushes.
3. Position the reverse gear idler assembly in to the gearbox
casing so that the reverse peg is located in the groove on
the idler gear.
4. Locate reverse shaft and using the slot turn the shaft to
allow the 7/16"UNF locking screw and lock washer to be
fitted.
Laygear assembly
1. Replace the thrust washers on to the layshaft using a little
grease. The 38.1 mm (1.5") o/d washer fits at the front of
the shaft.
2. Fit new laygear bushes.
3. Position the laygear in position on the shaft and secure the
31.75 mm (1.25") o/d thrust washer using a little grease.
4. Ensure that the thrust tabs are correctly located in the slots
provided.
Primary gear assembly
1. To dismantle the primary gear assembly, remove the circlip
and spacer washer and press off the bearing. Note that
st nd
/2 fork has a
rd th
/4 fork.
there is a retaining clip on the front of the primary bearing.
Ensure that it is fitted when the bearing is replaced.
2. Using a suitable extractor, remove the primary bush.
3. Replace all worn parts as required and refit primary gear
assembly to gearbox. Note that if a little gentle heat is used
at the bell housing this will assist it the fitting of the primary
gear assembly.
Mainshaft assembly
1. Remove the 3
from the front of the mainshaft after depressing the
mainshaft plunger and turning the mainshaft collar. Note
be careful not to lose the plunger spring.
2. Remove plunger and spring.
3. Remove 3
nd
collar, 2
mainshaft.
4. Depress 2
mainshaft collar, turn and remove.
5. Remove 1s2 speed synchro body complete with 1
gear.
6. Replace all worn parts as required and reassemble in
reverse order.
st
Synchro bodies, 1
1. Press the body through the gears, after first overcoming the
tension of the six body springs. Note It is advisable to carry
out this operation with the body wrapped in a suitable
piece of cloth in order to avoid losing any of the six balls
and springs.
2. Examine the gears and replace worn parts as necessary.
3. Reassemble in reverse order ensuring that the six flats on
the splines of the first gear line up with the six balls in the
first speed synchro body. Refit the mainshaft cluster to the
gearbox.
4. Turn gearbox carefully on to its top face and using a
suitable tool, align the laygear and thrust washers with the
layshaft holes in the case.
5. Inspect the layshaft and replace if worn, then refit to
gearbox. Note The tag end of the layshaft must face
towards the front of the gearbox.
6. Hold temporarily in position with the front cover, securing
with two nuts.
Rear bearing housing assembly
1. Unscrew the single No. 10 UNF set screw, complete with
lock washer, securing bearing housing to rear of gearbox.
2. Remove the bearing housing retainer, and then withdraw
the bearing housing from the mainshaft.
3. Release the circlip retaining bearing in housing.
Page 44
rd th
/4 body, complete with synchro sleeve
rd nd
speed gear and bearing, 2
nd
speed gear and 2 speed bearing from
nd
mainshaft plunger, located below 2
nd
2 and top
rd
/3 speed thrust
nd
speed
st
speed