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F.3 DISMANTLING THE THIRD MOTION SHAFT
Remove the following items in this order: baulk ring; synchromesh sleeve and hub; second baulk ring.
If the synchromesh sleeve is removed from the hub take care not to lose the three locating balls and
springs which will be released in consequence. Press down the third speed gear cone thrust washer
plunger; rotate the thrust washer to align its splines with those on the shaft and remove the washer.
Withdraw the third speed gear and its splined bush.
Withdraw the bush interlocking washer to release the second speed gear with its bush and baulk ring.
Remove the thrust washer from the splines on the shaft and withdraw the first and second speed hub
and gear; if necessary slide the gear from the hub, taking care not to lose the three balls and springs.
Tap up the locking tab and unscrew the rear retaining nut; withdraw the washer, speedometer drive
gear and key and the distance sleeve from the shaft.
Press the rear bearing and housing from the shaft.
F.4 ASSEMBLING THE THIRD MOTON SHAFT
Assemble from the front end.
1. Locate the rear thrust washer on the front end of the splines, ground face to the front.
2. Push the longer brass bush up to the splines with the dog towards the front.
Note-This bush must be fitted so that the oil hole is in line with the one in the shaft and the cut-
away portion of the third speed splined bush will be over the locating peg hole when the dogs
of the two bushes are engaged with the bush interlocking washer.
3. Fit the second speed baulk ring and gear onto the bush with the plain side of the gear towards
the front.
4. Slide on the bush interlocking ring and the shorter splined bush, locating the dogs of both
bushes in the interlocking ring.
5. Insert the spring and locating peg into the hole in the shaft.
6. Fit the third speed gear onto the bush with the cone towards the front.
7. Thread on the front thrust washer, machined face towards the gear, while holding down the
locating peg with a thin punch through the hole in the gear cone, and push the washer over it;
turn the washer to allow the locating peg to engage in one of the splines.
8.
Fit the three springs and balls to the third speed synchronizer and push on the synchronizer
sleeve (striking dog).
9. Push on the top and third gear synchromesh assembly hub with its two baulk rings. The plain
side of the hub faces the rear.
10. Assemble the following items from the rear:
a. Insert the three balls and springs in the second gear hub and push the synchronizer
sleeve (striking dog) into position on the hub.
b. Fit the first speed gear and synchromesh hub assembly, and the baulk ring, to the
splines on the shaft.
c. Press the rear bearing into its housing and fit it to the shaft, outer flange of the
housing to the rear.
d. Push on the distance sleeve, speedometer drive gear and key, lock washer and nut.
F.5 LAYSHAFT GEAR
The assembly sequence of the layshaft bearings is as follows: a circlip at the rear, a needle race, a
single long distance tube, a circlip, a needle race, a circlip, a needle race, a circlip, two races being
fitted at the front end and one at the rear.
When assembling, fit a circlip to the innermost groove in the gear, pushing it in from the front, or large
gear, end.
Hold the layshaft vertically in the vice, stepped end downwards.
Smear the shaft with grease and assemble a roller bearing on the shaft against the vice jaws and then
slide the gear cluster over the shaft and the bearing with the large gear downwards.
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