Lotus TURBO ESPRIT Service Manual page 270

SECTION FB
Page
7 7
3. Slide off the 3rd gear drive pinion with the synchro ring and the needle bearing
cage,
4. If
the clutch shaft i s fitted, remove the circlip securing the clutchshaft to the
primary shaft and remove the clutch shaft and spring.
TO
Replace
1 . If
the clutch shaft is disconnected,
fit
the spring
(0),
then the clutch shaft
(M)
and secure with the circlip
(J).
2.
Fit the following onto the primary shaft inthe order shown.
(a).
3rd drive gear (P) together with its needle bearing cage coated
with transmission oil.
(b)
.
Sync hro ring
(F)
.
(c).
Synchroniser
(E)
ensuring that the collar with a groove i s towards
the 3rd drive gear
(P).
(d).
Using the circlip pliers
TOOOT0620
f i t the circlip
(Q).
Make sure circlip
is fitted i n the direction noted when removed.
IMPORTANT: The maximum movement of the synchroniser(E) on the shaft
must not exceed
0.1 0
rnm. Adjustment of this movement i s
achieved by changing the circlip
(Q)
for one of a different
thickness.
(e)
.
Synchro ring
(D)
.
(f).
4th drive gear
(R)
together with its needle bearing cage coated with
transmission oil. Slide the synchroniser
(E)
across to engage the 4th
drive gear.
3.
Pass the input shaft end ofthe assembly through the top openingof the
gearbox, then forward through the bearing opening into the differential
compartment and locate circlip i n i t s groove.
It
may be necessary to remove
the pinion shaft to provide additional space to move the primary shaft down
into the casing. See under heading 'Bevel Pinion Shaft'.
4. F i t
the double rear bearing
(C)
and the front bearing
(H)
using a tube
30
mrn
internal diameter,
300
m m long.
5.
Replace the bevel pinion, see 'Bevel pinion Shaft'.
6.
Place the reverse gear wheel down into the gearbox with the fork groove
towards the differential. Insert the intermediate shaft and line up'the recess i n