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mm
0002
0009
In
Clrcllps
are
available
m
5
Slles
from
160
180mm
0063
0071m
Fit the 1
st
speed
gear and baulk ring
on
the
rear
of the shaft
wIth
the
COnical
end
facmg
the
rear
F
It
the first
speed
synchronlser
and the
reverse
gear
assembly
on
the shaft
Fit the spacer and press the mamshaft
bearing
and
retamer
on
the shaft
FIt spacer
ball and
speedometer
drive
worm
uSing
a
S
JItable
Clrcllp
to
secure
the drive
worm
With
an
end float of
005
022
mm
0
002
0009
m
Clrcllps
are
avaIlable
m
8
sizes
from 1 30
1 70
mm
0051
0067
m
m
thickness
Check the end float of the
gearwheels
as
shown
m
Fig
G 26
whIch should be
as
follows
1
st
speed gearwheel
2nd
speed
gearwheel
005
022
mm
0002
0009
m
o 1
022
mm
0004
0009
m
Fit the
mam
drive
gear
clutch shaft
and
the mamshaft
assembly
mto
the
gearbox
casmg Fit selector rods and selector
forks
as
follows
Turn the casmg
so
that the detent ball hole
IS
uppermost
Fit
the spring and the ball
m
the bottom hole
Fig
G 27
Hold the
ball With
a
dummy
shaft and fit the 1
st
reverse
selector fork
and the rod
pushmg
the
dummy
shaft
out
F
It
the
Interlocking
plunger
2nd 3rd
speed
selector fork and rod and
Insert
the ball
and the spring
Screw down the
mterlockmg
plug
coatmg the
thread With
sealing
compound
Secure the selector forks
to
the
rods With the retalnmg pins
Fit the
reverse
Idler gear and shaft and
secure
With lock bolt and
plate
F
It
the countergear cluster and the shaft usmg
a
SUitable
thrust washer
to
obtarn
an
end float of 0 04
0 12
mm
00016
00047
In
Washers
are
available
rn
5
sizes
from 383
403
mm
0 151
0159
In
m
thickness
Fit the
cross
shafts
11
Fig
G 7
thrust washers
2 and operatmg
levers
3
Secure
cross
shafts With
retammg
rings
5
and lock
the operatmg levers
to
the shafts With the
pms
4
Fit the
rear
extension
casmg
to
the
gearbox
case
and
tIghten
the
bolts
to
a
torque of 22
30
kgm
16
22 Ib ft
Fit the
speedometer
driven piniOn
set
bolt and
lockrng
plate
Check
the gear backlash
as
shown
rn
Fig
G 28 which should be 008
o 13
mm
0 003
0 005
In
for all gears
F
It
the front
cover
and
tighten
the bolts
to
1 1
1 7
kgm
8 0
12 2 Ib ft
Refit
the clutch Withdrawal and release
bearmg
and the bottom
cover
tlghtenmg
the bolts
to
a
torque
readmg
of 1 1
1 7
kgm
80
123 Ib ft
THREE SPEED GEARBOX
Installation
The mstallatlon of the
gearbox
IS a
reversal of
the removal
procedure
Note the
follOWing
pomts
Fill the
gearbox
With the recommended MP 90 011 The
flllmg
capacity
IS
1 7 IItres 045 U S
gall
0 37
Imp gall
AdjUst
the
clutch slave
cylinder push
rod
to
obtain
a
withdrawal lever free
play
of 2 2
mm
0087
m
FOUR SPEED GEARBOX
Removal and Installation
I
Follow the
mstructlons
for the three
speed
gearbox
except
that
the four
speed
gearbox
s
a
floor mounted
gearlever
whIch
should be removed
at
the control lever bracket
FOUR SPEED GEARBOX
DIsmantling
NOTE
There
are
two
types
of
synchromesh
used
m
thiS
gearbox
Borg
Warner and
Servo
The
Borg
Warner type
IS
deSCribed
In
Three
speed
gearbox
Dram the
gearbox
011
Remove the dust
cover
the
retainer
spring
Withdrawal lever and clutch release
bearing
Rem ove
the
cleVIS
pin
holdmg
the
strlkmg
rod
to
the
control
lever
F Ig G
311
speedometer
driven p
In Ion
assembly
rear
extension
housmg
dlsengagmg
strlkmg
rod from the selector rod gates
see
Fig
G 32 and
unscrew
the top and bottom
covers
Unscrew the detent ball
plugs
and
remove
the springs and
detent balls
Drive
out
the selector fork
to
rod retalnmg pinS
and
remove
the selector rods and forks
Engage
the second and
fourth gear
by pushing
the operatmg sleeve of the correspon
dmg
synchronizer
unit to
the given gear pOSItions and slacken
the
main
shaft
nut
Remove the countershaft and the gear cluster
together
With the
two
needle roller
bearings
and the spacers
Remove the
reverse
gear
clrcllp
and
remove
the
reverse
Idler gears and the shaft
Fig
G 33
Remove the four bolts
holding
the malnshaft
bearing
retamer
and
remove
the
retamer
Fig
G
341
Withdraw the mamshaft
assembly
as
shown
In
Fig
G 35 and the
main
drive shaft clutch
shaft
To
dismantle the
malnshaft
Fig
G 36
release the 3rd 4th
synchrOnizer
Unit
clrcllp
and
pull
off the hub
complete
With the
operating
sleeve
Remove the third
speed gearwheel
and the
needle roller
bearing
Remove
the
mam
shaft
nut
and the
locking
plate
and
the
speedometer
drive
worm
With
the
retamlng
ball
Then WIthdraw the mamshaft
reverse
gearwheel
and the hub
and press off
the
ma
Inshaft
bearing
retainer
and
the
bearing
Next
remove
the thrust washer and the first
speed gearwheel
together
With the needle roller
bearing taking
care
not to
loose
the small thrust washer
locating
ball
Slide off the first
speed
gearwheel
bush
Finally
remove
the second
speed
gearwheel
together
With the needle roller
bearing
FOUR SPEED GEARBOX
Inspection
Follow
the
mstructlons
for
the
three
speed
gearbox
In
accordance
With
the
speCifications
given
m
section
TECHNICAL
DATA
FOUR SPEED GEARBOX
Assembly
The
assembly
IS
carried
out
m
Similar
manner
as
deSCribed for
the three
speed
gearbox
except
for the
followmg
pomts
When
mstalllng
the
mam
drive shaft
clutch shaft
select
a
SUitable
clrcllp
to
eliminate any end float
Clrcllps
are
available
m
5
Slles
from 1 52
1 77
mm
006
007
m
m
thickness
47
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