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7.
Locate the first/second synchro body on the mainshaft
and press in to position.
8.
To facilitate further assembly, position the mainshaft
in an assembly "pot" or a vice.
9.
Fit the three springs and plungers to the third/fourth
synchro body.
10.
Slide the third/fourth synchro sleeve over the synchro
body leaving sufficient room to enable fitment of
thrust blocks and balls in the following operation.
11.
Fit three thrust blocks leaving the synchro body ball
seatings completely visible.
12.
Seat the synchro body ball in the thrust block, press
the ball down on to the plunger and slide the thrust
block between the sleeve and the synchro body.
13.
Repeat instruction 12 for the two remaining balls.
14.
Slide the third/fourth synchro sleeve along the synchro
body until it "clicks" in to position. Note: Ensure that
the sleeve is not pushed in too far, otherwise the
synchro balls and thrust blocks will be disturbed.
15.
Reposition the mainshaft in a vice or assembly "pot" to
facilitate first/second synchro body assembly.
16.
Fit springs and plungers to the synchro body.
17.
Slide first/second synchro sleeve over synchro body
leaving sufficient room to enable fitment of thrust
blocks and balls. Ensure the teeth of the synchro
sleeve are facing forward.
18.
Fit the three thrust blocks, leaving synchro ball
seatings completely visible.
19.
Seat synchro body ball in thrust block, press ball down
on to plunger and slide the thrust block between the
sleeve and synchro body.
20.
Repeat instruction 19 for two remaining balls.
21.
Position baulk ring on first speed gear.
22.
Fit first speed gear bush key into its location in the
synchro body.
23.
Apply "Moly grease 799" to gear bush outside
diameter and inner flange face and then fit first gear.
24.
Position first gear, including bush and baulk ring, on to
mainshaft splined end.
25.
Rotate first gear bush, until it fully locates in the bush
key seated in the first/second synchro body. Note:
Handle mainshaft cluster with care to prevent synchro
sleeves etc. from being disturbed.
26.
Using tool No. RT 7490 press the rear cover on to the
mainshaft.
Primary gear assembly - dismantling and re-assembly
To dismantle
Prise the primary gear front seal from the gear shaft.
1.
2.
Using circlip pliers (Tool No 7066) remove circlip
securing the front bearing to the primary gear.
3.
Remove the spacer and front bearing.
4.
Withdraw the needle roller bearing from inside the
gear body.
5.
Inspect parts for wear, renewing if necessary.
To re-assemble
Replace components in reverse order. care should be taken when
fitting the front seal that it is not damaged when passing the seal over
the shaft splines. The seal is correctly fitted when it abuts the
shoulder on which is the circlip. It must not abut the circlip.
Note: The lip on the front seal must face forward.
Lay gear - dismantling and re-assembly
1.
Examine the lay gear assembly, gear teeth and renew
complete assembly if obvious wear or damage is
apparent.
2.
The lay gear needle rollers should also be checked.
remove worn items with a suitable drift. Care should
be taken when fitting new needle roller bearings not
to damage the bearing cage
3.
If signs of scoring are apparent on the layshaft, due to
worn needle roller bearings, it will have to be
renewed.
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.
Page 49
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