Assembly - Triumph Thunderbird Service Manual

Inspection
1. Examine all gears, bearings and bushes and thrust
washers for damage, distortion, chipped teeth and
wear beyond the service limits. Replace all suspect
components and always use a new circlip to
assemble the shaft.
Assembly
Note:
• Lubricate each gear, thrust washer and bush
with clean engine oil during assembly.
Bushes with oil holes must always be MISALIGNED
with the corresponding oil holes in the output shaft.
Reduced oil pressure and gear lubrication may result
from alignment of the oil holes, which would cause
premature wear of engine and transmission
components.
When using a press, always wear overalls, eye face and
hand protection. Objects such as bearings frequently
break-up under load and the debris caused during
break-up may cause damage and injury to unprotected
parts of the body.
Never wear loose clothing, which could become trapped
in the press and cause crushing injury to the hand, arms
or other parts of the anatomy.
1. Assemble the plain bush (16) and first gear <17>, with
the dog ring slots facing away from the circlip
groove, to the output shaft (14).
1. Output shaft
2. Plain bush
3. First gear
4. Circlip groove
Transmission
2. Fit the thrust washer (18).
3. Place the output shaft inner bearing (19) on press
bars, ensuring that the press bars support the inner
race of the bearing and the locating pin on the outer
race will be facing towards first gear when fitted to
the shaft.
1. Output shaft
2. Bearing
3. First gear
4. Press bars
4. Locate the output shaft (19) to the bearing, with the
circlip groove pointing through the bearing (i.e. away
from the press).
5. Press the output shaft through the bearing until the
thrust washer contacts the bearing face.
6. Fit a new circlip (20).
Z Working from the opposite end of the shaft, slide on
the fourth gear and first gear dog ring (15). Ensure
that the larger dogs face towards first gear
(17).
8. Fit the plain bush
(12)
and fourth gear, ensuring the
dog ring slots face the dog ring.
9. Fit fjfth gear (11), and the plain spacer (10).
10. Fit sixth gear (9).
11. Fit the splined bush
(7)
and third gear
(8),
with the
dog ring slot facing away from sixth gear.
12. Fit the splined spacer (6) and the second and third
gear dog ring (5).
13. Fit the plain bush (4) and second gear (3) with the
dog ring slots facing towards the dog ring (5).
SelVice Manual - Thunderbird
7.9