Reliant Rebel 700 1967 Workshop Manual page 45

4. Using a suitable press tool or drift remove rear bearing from
the housing.
5. Examine all components for wear, replacing if necessary.
Reassemble in reverse order.
Reassembly of selector forks
1. Fit coupling washer, tab washer and 7/16"UNF bolt,
tightening to a torque of 6.91kg/m (50lb/ft). Bend over the
tab washer to secure.
2. Turn the gearbox on to its base and fit the 1
selector forks. Note 1
rd th
3 /4 fork.
3. Secure interlock pin in to 1
grease. Refit to gearbox, together with associated fork lever
and selector fork.
st nd
4. Turn the 1 /2 shaft and fork through 180° so that the grub
screw can be fitted, then turn back to normal position.
5. Turn gearbox on to left-hand side and insert the 3
shaft interlock ball in to its location.
6. Fit selector shaft in to gearbox case through the fork lever
and selector fork, securing with 5/16"UNF cone screw.
7. Turn the gearbox on to its base and insert the reverse shaft
interlock ball in to its location.
8. Fit selector shaft in to gearbox case through the fork lever
and secure with 5/16"UNF cone screw. Note Ensure that
the reverse fork is engaged in the reverse gear lever.
9. Treat all cone screws with "Loctite" and peen over to
secure.
Front cover
1. Check front cover oil seal and replace if necessary using tool
No. RT 7488 (Figure 3).
2. Fit a new gasket and secure front cover to gearbox case
with seven ¼"UNF nuts and washers. Note To prevent the
primary gear damaging the oil seal when fitting front cover
use a sleeve as shown (Figure 4).
Clutch operating fork
1. Position the operating fork in its support bracket and secure
with 5/16"UNF nut and bolt.
2. Refit the rubber gaiter over the fork and locate in the bell
housing.
Remote control housing assembly
To dismantle
1. Remove the rubber plug from the gearbox top cover and,
using a 3.175mm (0.125") drift tap in the roll pin to release
the selector toggle from the shaft.
st nd
/2 and 3
st nd
/2 fork has a shorter boss than
st nd
/2 selector shaft using a little
rd
/4
2. Remove the rubber grommet from rear of remote housing
and carefully withdraw the gear change shaft.
rd th
/4
Figure 3 Replacing front cover oil seal
th
Figure 4 Refitting front cover (plus sleeve dimensions)
3. Using a 2.381mm (0.093") drift tap in the two roll pins
securing the remote control housing to the housing tube.
Note Early versions used screws and lock washers.
4. Repeat the operation for removing the gearbox top cover.
5. Examine the oil seals and replace if necessary.
To reassemble
1. Locate both oil seals in their retainers in the remote control
housing tube.
2. Fit the housing tube in to the gearbox top cover and the
remote control housing and secure with either roll pins or
screws and lock washers. Tap in the roll pins until they are
flush with both housings.
3. Insert the gear change shaft in to the remote control
housing and locate selector toggle in the gearbox top cover.
4. Secure with roll pin.
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