Reliant Rebel 700 1967 Workshop Manual page 50

Reverse idler gear assembly and shaft
1. Check reverse idler gear teeth and renew assembly if
necessary.
2. Inspect bushes and if worn, drive out old bushes with
a suitable drift and fit new ones. Ensure the end face
of the bushes finish flush with the gear face,
3. Check gear shaft for scoring and replace if necessary.
To re-assemble the gearbox
1. Refit reverse idler gear and shaft in to the gearbox
case with the select groove to the rear.
2. Position the laygear assembly with its thrust washers
in to the base of the gearbox.
3. Refit the primary gear assembly in to the bell housing
location. Note: Drive carefully in to position until the
bearing retaining ring is flush with the case.
4. Feed in the mainshaft assembly, taking great care not
to dislodge the synchro thrust blocks and balls.
5. Refit the rear cover with a new gasket to within 6.35
mm (¼ in) of the gearbox face (to allow rotary
movement and facilitate positioning of the layshaft).
6. Turn the gearbox on to its top face and slide the
layshaft through the thrust washers and laygear
assembly until it mates in its bore with the rear of the
box. Note: The tang end of the layshaft must be at the
front.
7. Position the tang end of the reverse shaft to engage
with the horizontal slot in the rear cover, then bolt the
rear cover fully home.
8. Return the gearbox to an upright position and insert
the reverse, 1st/2nd and 3rd/4th selector forks on to
the shafts.
9. Replace the two interlock balls in to the cross drilling
in the bell housing, locating in position with grease.
10. Line up the reverse selector shaft in the selector fork
and drive home the mills retaining pins.
11. Ensuring the interlock pin is in position, replace
the1st/2nd selector shaft in the selector fork and
lever. Secure in position with the mills pin. Note:
Rotate the shaft and fit the horizontal pin first, in the
selector lever, before pinning to the selector fork.
12. Replace 3rd/4th selector shaft into the mating fork
and lever, again retaining in position with mills pins.
Refit front cover. Note: Ensure that the oil seal is
13.
correctly positioned on the primary gear shaft. Secure
front cover to gearbox with seven nuts and lock
washers. Do not attempt to move selectors or change
any gear until the front cover is secured as this will
result in forcing the mainshaft assembly apart
14. Replace the selector shaft detent balls and springs and
refit top cover and gasket, retaining in position with
eight set screws and locking washers.
15. Refit the gearbox extension and secure with six ¼"UNF
nuts and lock washers.
16. Refit the clutch fork and lever assembly.
Gearbox specification
Four forward speeds and reverse with synchromesh on all forward
gears.
Ratios:
Oil capacity
Page 50
Top 1.000:1
rd
3
1.320:1
nd
2 2.040:1
st
1 3.880:1
Reverse 3.250:1
0.99 litres (1,75 pints)