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5.
Replace top cover plug and remote control housing
grommet.
Gearbox extension assembly
1.
Using a suitable internal extractor tool, remove the gearbox
extension rear seal. Check for wear and replace if
necessary.
2.
Slacken the 5/16"UNF lock nut and unscrew the
speedometer drive gear stop.
3.
Unscrew two ¼"UNF set screws, complete with lock
washers and remove speedometer pinion thrust bush and
gear assembly.
4.
Remove the gear assembly from the thrust bush and check
for wear. Renew if necessary.
5.
When replacing the speedometer driven gear and thrust
bush, ensure that the lock nut and screw are securely
tightened to prevent lateral play in the gear.
6.
Check the rear flexible gearbox mounting for wear or
excessive movement. If the rubber has broken, this
component will need renewing. A press tool will be needed
to remove or replace the rubber bush.
To reconnect the remote control assembly to gearbox
1.
Fit a new gasket and locate extension to gearbox studs,
securing with six ¼"UNF locking nuts.
2.
Insert the detent balls and springs in to the gearbox casing.
3.
Position a new gasket on the top cover seating and fit the
remote assembly, securing with six ¼"UNC set screws and
lock washers.
4.
A single ¼"UNF set screw and lock washer, supports the
remote control housing to the mounting bracket which is
secured to the extension with two 5/18"UNF set screws and
washers.
5.
Replace dipstick (if fitted).
Gearbox specification
Four forward speeds and reverse, synchromesh on second, third and
top gears.
Ratios:
Oil capacity
The remote control mechanism is not fitted to vehicles fitted with the
all synchromesh gearbox. On these vehicles the gear lever is mounted
directly to the gearbox top cover.
Top
1.000:1
rd
3
1.454:1
nd
2
2.461:1
st
1
4.267:1
Reverse 5.493:1
0.85 litres (1.5 pints)
All synchromesh gearbox (from chassis No. 941001)
Gearbox removal and refitting (Figures 5 & 6)
To remove
1.
Disconnect battery leads.
2.
Remove gear lever gaiter.
3.
Jack up the vehicle and place securely on axle stands.
4.
Drain gearbox oil.
5.
Disconnect speedometer cable.
6.
Unscrew rear gearbox mounting bolt and remove rear cross
member, noting position of earth braid.
7.
Release spring clip and disconnect balance spring and
withdraw gear lever.
8.
Disconnect clutch rod from pedal lever and clutch operating
fork. On 750cc engines remove the clutch slave cylinder and
tie back safely.
9.
Disconnect starter motor cable, unscrew two 3/8"UNF nuts,
lock washers and bolts and remove starter motor (might
need to remove oil filter for access).
10. Remove engine stabiliser rod (if fitted).
11. Disconnect prop shaft from rear axle (4 x 5/16"UNF nuts,
lock washers and bolts) and withdraw from gearbox.
12. Remove 2 x 5/16"UNC bolts and 6 x 5/16"UNF nuts
complete with lock washers holding gearbox to rear of
engine.
13. Support the gearbox and slide it rearwards from the engine.
To re-install
1.
Raise the gearbox to the engine, slide forwards and locate
on the six studs and secure the two assemblies together
using the 2 x 5/16"UNC bolts and the 6 x 5/16"UNF nuts
complete with lock washers.
2.
Slide the prop shaft sleeve yoke into the rear of the gearbox
engaging on the splines and secure the rear to the axle
flange with 4 x 5/16"UNF nuts, bolts and lock washers.
3.
Refit the starter motor using 2 x 3/8"UNF nuts, bolts and
lock washers. Re-connect the starter motor cable.
4.
Reconnect the clutch rod to clutch operating fork and pedal
lever. On 750cc engines refit the clutch slave cylinder.
5.
Using 8 x 5/16"UNF set screws and nuts secure the rear
cross member to the chassis.
Page 46
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