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PART 6-3-3
SPEED FULLY SYNCHRONISED MANUAL SHIFT
6-21
FIG. 39-First and Reverse Synchronizer
Disassembled
LARGE
BIMETAL
"' " "
w' 7
CLUSTER GEAR
BIMETAL
THHUST
It/ASHER
STEEL
THRUST
WASHER
FIG. 40-Countershaft and Cluster Gear
assembly into third gear position, so
that extended detent notch of the cam
retains the ball and
spring. (Interlock
sleeves are
selectively
fitted for axial
movement of ·002 to
·010
in all gear
selection positions. Three sizel' are
available, refer
specifications
page
6-35).
5.
6 Cyl. Install lubricated reverse
idler gear and bush assembly and
shaft with bevelled ends of the gear
teeth forward. Shaft must be inserted
so that the locking groove is flush
with the outside face of the gear case,
and face towards the cluster gear
shaft hole. Refer Fig. 22, page 6-15
6. 8 Cyl. Instali
(22)
needle rollers
and
(2)
thrust washers with a dummy
shaft. A dummy
shaft
can be made
up from an old cluster shaft. Cut off
at
1
nr
inches.
7.
Assemble cluster gear, dummy
countershaft
(7111
C)
and bearings
as follows:
Insert dummy countershaft and
spacer
into cluster gear. Fit a set of
22 lubricated needle rollers at the
front
(largest
gear end) of the cluster.
Fit two sets of 22 lubricated needle
rollers at the other end of the cluster,
separating the rollers with cluster
gear needle roller retainer was?er.
Fit cluster gear needle roller rctamer
washers at each end of the dummy
countershaft, together with two thrust
washers at the rear
(small
steel
washer to cluster, engage tangs with
slots in gears)
(small
bimetal to case,
engage tangs with slot in case) of the
cluster gear, and one thrust washer
(large
bimetal engage tang with slot
in case) at the front end of the gear.
These may be retained with grease
(Refer
Fig. 40).
8. Place cluster assembly in the
bottom of the gear case, ensuring
that the tabs of the thrust washers
fit the grooves of the case (Fig. 41
).
9. Assemble first and reverse
speed
synchro assembly as follows:
Lubricate synchro
sleeve
and re-
verse gear and fit to the inner hub
with the teeth of the gear and the
FIG. 4 1-Ciuster Gear in
Case
synchro spring groove of the inner
hub at the
same
ends. Fit three first
speed shifting plates into the hub
slots, with plate pads in the recessed
end of the hub. Fit two
synchro
springs under the
shift
plates, the
white painted
spring
in the
spring
groove of the hub,
the
other
~n
the
hub end recess. Note that the
springs
are not identical. The
spring tangs
should locate on opposite
sides of
the
same shift
plate,
so
that
the spring
openings do not line up.
(See
Fig. 39).
10.
Assemble
second and
third
speed
synchro
as follows:
Fit lubricated
synchronizer sleeve
to inner hub
with sleeve selector
groove and hub inner
spline
pro-
trusion at opposite ends. Slide sleeve
across hub until three
second
and
third speed
shift
plates
can
be fitted
into the
slots in
the
inner
hub. Fit
two
second
and third
speed synchro
springs
under the
shift
plates behind
the pads. Note that the
spring
tangs
should be located
in
the
same shift
plate. The
springs should
be installed
with the
free
ends opposite.
(Fig.
25,
page
6--15 ).
11.
Lubricate first
speed
gear bore
and fit
with
blocker ring to output
shaft.
The back
face of
the gear
should
be against the rear
face
of the
mainshaft
shoulder.
Fit first
speed
synchro
and reverse
gear sleeve
assembly, and
snap
ring to output
shaft with reverse
gear
sleeve teeth
toward rear
of case.
Check
end float;
this
should
be
within
the limits
·006" to
·019''.
Fit output
shaft
bearing,
spacer, ·and snap
ring, (Fig.
47), selecting snap ring
to keep
end
float to
a
minimum
(-
004
max.).
Do
not fit
snap
ring to
outside diameter
of output
shaft
bearing (Fig. 42).
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