Reliant Rebel 700 1967 Workshop Manual page 48

6. Fit the gearbox mounting bolt and reconnect the earth
braid.
7. Reconnect speedometer drive cable.
8. Refit engine stabiliser rod (if fitted).
9. Refill the gearbox with the recommended oil.
10. Remove stands and jack down the vehicle.
11. Replace gear lever.
12. Reconnect battery
13. Adjust clutch (700cc engines).
Dismantling the gearbox (removed from vehicle) (Figures 5&6)
To dismantle the gearbox
1. Drain the gearbox oil.
2. Remove the clutch fork and lever assembly.
3. Unscrew eight set screws, with lock washers and
remove the top cover, gasket, selector springs and
detent balls.
4. Remove seven nuts and lock washers and remove the
gearbox front cover.
5. Using a suitable drift, tap out the roll pins from the
3rd/4th selector fork and lever, then withdraw the
selector shaft through the bell housing. Remove the
selector lever.
6. Repeat the above for the 1st/2nd fork and lever and
withdraw the shaft taking note of the interlock pin in
the end of the shaft.
7. Tap out the roll pin from the reverse selector lever and
withdraw the selector shaft through the bell housing.
8. Lift out the selector forks and tilt the gearbox to
remove the two interlock balls from the cross drilling
in the bell housing end of the selector shaft bores.
9. Withdraw the lay shaft into the bell housing, allowing
the lay gear to drop in to the base of the gearbox.
10. Unscrew six set screws complete with lock washers
and withdraw the rear cover and main shaft assembly,
taking care not to displace the front or rear synchro
sleeves.
11. Tap out the primary gear shaft from the bell housing.
Note: When separating the main shaft from the
primary gear shaft the needle roller pilot bearing may
remain on the mainshaft.
12. Lift out the laygear assembly and the two thrust
washers.
13. Withdraw the reverse gear shaft through the rear of
the gearbox and lift out the reverse gear.
14. Remove the rear cover from the mainshaft assembly.
Mainshaft dismantling and re-assembly
To dismantle
1. Remove the first speed gear, bush and bush key
complete with baulk ring from the mainshaft.
2. Remove the first/second gear selector sleeve. Note: It
is advisable to carry out this operation with the sleeve
wrapped in a suitable piece of cloth which will avoid
losing any of the sets of balls, blocks, springs and
plungers from the synchro body.
3. After removing the sleeve, recover the springs, balls,
blocks and plungers from the cloth.
4. Repeat this operation for the third/fourth selector
sleeve.
5. Remove the circlip from the spigot end of the
mainshaft.
6. Using tool No. RT 8778, remove the third/fourth
synchro body from the mainshaft.
7. Withdraw the first speed gear bush key. Using tool RT
8778, remove the first/second synchro body from the
mainshaft and remove the second speed baulk ring.
8. Remove the second/third speed gear from the
mainshaft.
9. Examine all components for wear and renew if
necessary prior to reassembly.
To reassemble
1. Apply "Moly Grease 799" to second/third gear running
faces on the mainshaft.
2. Fit the third speed gear and baulk ring on the
mainshaft.
3. Secure the woodruff key in its seating on the
mainshaft.
4. Locate the third/fourth synchro body on the mainshaft
pressing in to position and fit the circlip.
5. Fit second speed gear and baulk ring to mainshaft
followed by the thrust washer. Ensure that the thrust
face of the washer abuts the gear.
6. Secure the second woodruff key in its location on the
mainshaft.
Page 48