Assembly
MAINSHAFT AND LAYSHAFT END FLOATNOTE:
^ The end float setting for both the mainshaft and the layshaft has to be determined before the gearbox can be reassembled.
^ This is achieved by damping the mainshaft and layshaft separately between the center plate and main casing and measuring the movement on each shaft with a Dial Test Indicator (DTI).
^ The end float setting for the mainshaft and layshaft is 0.01 - 0.06mm (0.0004 - 0.0024 inch).
^ Shims to make up the required clearances are placed under the bearing races of the center plate.
SHIMMING
1. Install bearing races to main casing front cover.
2. Install front cover to casing without oil seal.
3. Clamp casing in vice with front cover downwards.
4. Install input shaft.
- Do not install 4th gear baulk ring.
6. Install mainshaft assembly to input shaft;
6. Install mainshaft bearing shim and track to center plate.
7. Install center plate and bolt down using 8 "slave" bolts.
8. It large ball bearing to rear of mainshaft.
9. Mount dial test indicator.
10. Rotate mainshaft to settle bearings.
11. Lie mainshaft and note reading.
12. Dismantle and substitute shims if reading incorrect.
13. Repeat procedure.
14. Remove mainshaft assembly and repeat procedure for layshaft.
15. Dismantle assembly in preparation for assembly on stand.
ASSEMBLING MAINSHAFT AND LAYSHAFT TO CENTER PLATE
1. Secure center plate to workstand.
2. Install selected shims and bearing races.
3. Install inboard detent ball and spring, use a dummy bar to temporarily hold the ball in place.
4. Check both synchromesh units are in neutral and install selector shah assembly to mainshaft.
5. Install mainshaft and selectors as complete unit to center plate aligning pin with slot in plate.
6. Install 4th gear synchromesh baulk ring.
7. Install layshaft while lifting mainshaft to clear layshaft rear bearing.
8. Lubricate pilot bearing and install input shaft.
9. Install oil seal to front cover.
- Ensure seal is installed down to shoulder.
- Apply Hylosil RTV 102 to front cover as shown.
NOTE:
^ Early type seal - unwaxed: lubricate seal with gearbox oil.
^ Later type seal - wax coated: install seal dry.
10. Install bearing races and clips to main case and install front cover.
- Seal fixings with Hylogrip 640.
11. Apply Hylosil RTV 102 and install main casing to center plate.
12. Bolt casing and center plate together using 2 or 3 "slave" bolts.
13. Install new O-ring and install spool retainer.
14. Remove casing from stand and clamp in vice.
REVERSE AND 5TH GEAR REASSEMBLY
1. Install mainshaft reverse gear selectable washer, bush and needle bearing.
2. Install mainshaft reverse gear and synchromesh baulk ring.
3. Install layshaft reverse gear.
4. Assemble selector spool, selector fork and reverse/5th gear synchromesh hub.
- Install as one assembly to mainshaft splines and selector shaft.
- (Ensure synchromesh baulk ring locates inside hub).
5. Install new circlip.
NOTE:
^ The fit of the circlip is controlled by the selectable washer behind the reverse gear.
^ Adjust to 0.005 - 0.055 mm (0.0002 - 0.0021 inch).
6. At 5th gear split needle bearing.
7. At 5th gear and 5th gear synchromesh baulk ring to mainshaft, install layshaft 5th gear.
8. Later gearboxes: At split washer to retain layshaft 5th gear.
NOTE: Bevelled side of washer must face towards gear.
9. Install new mainshaft thrust collar roll pin.
- Locate 5th gear thrust segments and retaining ring.
10. Using LRT-37-023 to hold layshaft 5th gear, tighten the layshaft 5th gear nut to 220 Nm.
11. Stake layshaft 5th gear nut.
12. Using tool LRT-37-015 and LRT-37-021 press mainshaft rear support bearing race to collar on mainshaft:
13. Apply small amount of heat and install layshaft rear support bearing.
14. Install center plate detent ball and spring.
15. In and tighten plug to 25 Nm.
NOTE: Patchlok plug may be re-used provided threads are undamaged.
16. Move selector shaft and check that detent bails can be felt to engage in detent.
EXTENSION HOUSING - TYPE A AND B GEARBOX - INSTALL
1. Remove all "slave" bolts from center plate and casing.
2. Install oil filter.
3. Apply Hylosil RTV 102 to mating surfaces and install extension housing ensuring oil pipe locates in filter and roller bearings are not dislodged.
CAUTION: Do not use force, if necessary, remove extension housing and re - align oil pump drive.
4. Bolt extension housing to center plate and main casing.
5. Apply Hylosil R1V 102 to extension case spool retainer, install retainer and tighten bolt to 8 Nm.
6. Using LRT-37-015 and LRT-37-21 press on mainshaft oil seal collar.
EXTENSION HOUSING - TYPE C GEARBOX - INSTALL
1. Lubricate a new selector shaft oil seal with gearbox oil.
2. Install selector shaft oil seal.
3. Install oil filter.
4. Apply Hylosil R1V 102 to mating surfaces.
5. Install extension housing ensuring oil pick - up pipe -locates in filter and drive locates in oil pump
CAUTION: Do not use force, if necessary, remove extension housing end re-align oil pump drive.
6. Install extension housing bolts and tighten by diagonal selection to 25 Nm.
7. Install spacer
8. Position speedometer drive gear on output shaft splines.
9. Using a round nosed punch, carefully tap speedometer drive gear into position.
10. Smear a new O-ring with gearbox oil and install to speedometer pinion housing.
11. Lubricate speedometer pinion with silicone grease.
12. EN speedometer pinion housing ensuring teeth of pinion mesh with those of driven gear.
13. Apply Hylosil R1V 102 and install 5th gear spool guide.
- Tighten bolt to 8 Nm.
14. Install selector shaft pin to selector shaft, install and tighten a new see - locking nut.
15. Install output flange to output shaft.
16. Install new O-ring and spacer.
17. Install new tab washer.
18. It output flange bolt and tighten to 90 Nm.
19. Lock bolt with tab washer.
EXTENSION HOUSING - TYPE D GEARBOX - INSTALL
1. Remove all "slave" bolts from center plate.
2. Install oil filter.
3. Apply Hylosil RTV 102 to mating surfaces and install extension housing.
- Ensure that oil pipe locates in filter and that roller bearings are not dislodged.
CAUTION: Do not use force, if necessary, remove extension housing end realign oil pump drive.
4. Bolt extension housing to center plate and main casing.
5. Apply Hylosil RTV 102 and install extension case spool retainer, install and tighten bolt to 8 Nm.
SELECTOR QUADRANT - TYPE A GEARBOX - INSTALL
1. Position selector quadrant to selector shaft.
2. Apply Loctite 270 to thread of a new setscrew.
- Fin and tighten screw to 25 Nm.
3. Move selector shaft to neutral position.
CAUTION: Ensure end of setscrew locates in hole in selector shaft.
GEAR CHANGE LEVER YOKE - TYPE B GEARBOX - INSTALL
1. Position gear change lever yoke on selector shaft with ball facing towards output shaft.
2. Apply Loctite 270 to threads of a new setscrew, install and tighten screw to 25 Nm.
CAUTION: Ensure end of setscrew locates in hole in selector shaft.
GEAR CHANGE LEVER YOKE - TYPE D GEARBOXES - INSTALL
1. Position gear lever yoke on selector shaft with ball facing towards output shaft.
2. Apply Loctite 270 to threads of new setscrew.
- At and tighten screw to 25 Nm.
CAUTION: Ensure end of setscrew locates in hole in selector shaft
REMOTE HOUSING - TYPE A GEARBOX - INSTALL
1. Apply Hylosil RTV 102 to mating surfaces and install to extension housing.
2. Position remote housing to extension housing and gearcase ensuring rollers locate in quadrant.
3. Install but do not fully tighten 3 bolts in positions shown.
TRANSFER BOX SELECTOR HOUSING - TYPE A GEARBOX - INSTALL
1. Smear a new gasket with grease and install to remote housing.
2. Position transfer box selector housing to housing.
3. Install but do not fully tighten 4 bolts.
GEAR CHANGE HOUSING - TYPE A GEARBOX - INSTALL
1. Smear a new gasket with grease and install to remote housing.
2. Position gear change housing to remote housing ensuring gear lever ball is correctly located.
3. It bud do not fully tighten 4 bolts.
4. Tighten remote housing, transfer box selector housing and gear change housing bolts to 25 Nm.
TRANSFER BOX SELECTOR HOUSING - TYPE B GEARBOX - INSTALL
1. Smear a new gasket with grease and fin to gearcase.
2. Position transfer box selector housing to gearcase, install 4 bolts and tighten to 25 Nm.
GEAR CHANGE HOUSING - TYPE B GEARBOX - INSTALL
1. Apply Hylosil R1V 102 to mating surfaces of extension housing.
2. Position gear change housing to extension housing ensuring that gear lever passes through center of gear change lever yoke and engages in the gate plate.
3. Fin bolts and tighten to 25 Nm.
REMOTE GEAR CHANGE - TYPE C GEARBOX - INSTALL
1. Apply lithium based grease to selector rod yoke.
2. Position remote gear change to extension housing ensuring selector shaft pin is located in selector rod yoke.
3. IN bolts, washers and mounting rubbers securing remote gear change to extension housing; do not tighten bolts at this stage.
4. IN bolts, washers and mounting rubbers securing bracket to extension housing.
5. Tighten all bolts to 30 Nm.
REMOTE GEAR CHANGE - TYPE D GEARBOX - INSTALL
1. Apply Hylosil RTV 102 to mating surfaces of extension housing and remote gear change housing.
2. Position remote gear change housing on extension housing.
- Ensure that gear lever ball is correctly located.
3. Install bolts and tighten to 25 Nm.
5TH GEAR STOP SCREW ADJUSTMENT - TYPE A GEARBOX
1. Select reverse gear.
- While applying light pressure to gear lever towards left, turn screw - clockwise until it contacts yoke.
2. Turn screw anti-clockwise until 25 mm free play is felt at knob, ensure 5th gear can be engaged.
3. Tighten locknut.
4. Check all other gears are selectable.
BIAS SPRING ADJUSTMENT - TYPE A GEARBOX
NOTE:
^ The purpose of this adjustment is to set both bolts so that the bias spring legs apply equal pressure on both ends of the gear lever moss pin when third or fourth gear is engaged
^ This will ensure that when the lever is in neutral, the gear change mechanism is automatically aligned for third or fourth gear.
1. Select third or fourth gear.
2. Adjust the two adjusting screws until both legs of the spring are approximately 0.5 mm clear of the cross pin in the gear lever.
3. Apply a light load to the gear lever in a left hand direction and adjust the right hand adjusting screw downward until the right hand spring leg just makes contact with the cross pin.
4. Repeat the same procedure for the left hand adjusting screw.
5. Lower both adjusting screws equal amounts until the radial play is just eliminated.
6. Tighten locknuts.
7. Return gear lever to neutral position and rock across the gate several times. The gear lever should return to the third and fourth gate.
BIAS SPRING ADJUSTMENT - TYPE B GEARBOX
NOTE:
^ The purpose of this adjustment is to set both bolts so that the bias spring legs apply equal pressure on both ends of the gear lever moss pin when third or fourth gear is engaged
^ This will ensure that when the lever is in neutral, the gear change mechanism is automatically aligned for third or fourth gear.
1. Slacken bias adjustment plate bolts.
- Select fourth gear and move lever fully to the right.
2. Tighten adjustment plate bolts.
3. Check adjustment is correct by selecting third and fourth gears.
4. Install sealing rubber to gear change housing, apply Hylogrip 640 to screws and install cover.
BIAS SPRING ADJUSTMENT - TYPE C GEARBOX
NOTE: The purpose of this adjustment is to ensure that when bias spring is correctly adjusted, the gear change mechanism is automatically aligned for 3rd or 4th gear selection when gear lever is in neural.
1. Adjust both bias spring adjustment bolts until a clearance of 0.05mm exists between both legs of bias spring and gear lever cross pin.
2. Apply a light load to move gear lever to the led and adjust right hand bolt until right hand leg of bias spring just contacts gear lever cross pin.
3. Move gear lever to the right and adjust left hand bolt.
4. Check that with gear lever moved fully to the left and right, spring legs just contact gear lever cross pin.
5. Select neutral then rock gear lever across the gate; when released, lever should return to 3rd/4th position.
6. Tighten adjusting bolt locknuts.
CLUTCH HOUSING - TYPE A GEARBOX - INSTALL
1. Position clutch housing to gearbox.
2. Install securing bolts.
NOTE: The 12 x 45 mm bolts must be installed through locating dowels.
3. Tighten bolts by diagonal selection to 72 Nm.
4. Install pivot post, install and tighten bolts.
5. Apply lithium based grease to pivot post, pads and push rod.
6. Position pads to clutch release lever, install release bearing.
7. At new clips to retain pads.
NOTE: Clips may become displaced in service with no loss of performance.
8. At release lever.
9. Apply lithium based grease to splines of input shah.
CLUTCH HOUSING - TYPE B GEARBOX - INSTALL
1. Position clutch housing to gearbox.
2. Install securing bolts.
NOTE: The 12 x 45mm bolts must be installed through locating dowels.
3. Tighten bolts by diagonal selection to 72 Nm.
4. Apply lithium based grease to pivot post, release lever, socket and push rod.
5. It a new "C" clip to pivot post, install post.
6. It spring clip to release lever, install but do not tighten bolt.
7. Position release lever to pivot post ensuring spring clip is located behind "C" clip; tighten bolt.
8. It clutch release bearing and retain using new clips.
NOTE: Clips may become displaced in service win no loss of performance.
CLUTCH HOUSING - TYPE C GEARBOX - INSTALL
1. Position clutch housing to gearbox.
2. It securing bolts.
NOTE: The 2 longest bolts must be installed at locating dowel positions.
3. Tighten bolts by diagonal selection to 72 Nm.
4. Apply lithium based grease to pivot post.
5. It release lever and clutch release bearing.
ADAPTOR HOUSING - TYPE D GEARBOX - INSTALL
1. Position adaptor housing to gearbox.
2. It securing bolts.
NOTE: The two longest bolts must tee installed allocating dowel positions.
3. Tighten bolts by diagonal selection to 72 Nm.
4. Apply lithium based grease to pivot post.
5. It pivot post and secure with two bolts.