If the torque converter housing has been removed,
temporarily replace it. The gearbox can again be positioned
standing on the face of the housing ready for assembly.
Layshaft Assembly
1 Smear bearing surface of shaft with JCB HP Grease
and fit needle roller bearings 1a (wider bearing first),
followed by 2nd gear 1b.
2 Fit the synchro assembly 2, then press fit the bearing
track 3a.
3 Slide 1st gear needle roller bearings 3b over the track.
Smear bearings with oil. Fit 1st gear 3c over needle
roller bearings.
4 Assemble 4WD transfer gear 4 over splines. On 2WD
machines slide spacer over splines.
5 Press bearing 5a and 5b onto the assembled layshaft.
Smear the bearings with JCB HP Grease.
Mainshaft Assembly
6 Smear bearing surface of mainshaft with JCB HP
Grease. Fit the needle roller bearings 6a and 6b.
Assemble 3rd gear 6c and synchro-cup 6d. Fit synchro
gear 6e.
7 Fit spacer washer 7a and oil retention washer 7b. Note
the correct way round of components 7a and 7b. Press
bearing 7c onto shaft and smear with JCB HP Grease.
8 Press bearing onto assembled mainshaft and smear
bearing with JCB HP Grease.
112-2
Section F Transmission
9803/3280
Section F
112-2
Issue 2*
Synchro Shuttle Gearbox
Gearbox - Assembly (cont’d)
4 5a
1b1a
5b
3c3b3a2
7c 7b 7a 6e 6d 6c
6b 6a
8
*
*
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