BG
FtG
6 :8
Main drive
gear
Key
to
Fig
6
:8 a
4th
speed
gear
b
Oil
deÍlector
washer
G
Spanner
reassembly and always
fit
new
gaskets,
Wash the
bearings in clean solvent and blow dry.
Do not
spin
the
bearings
with compressed air or they will ber
damaged. After a
thorough cleaning, lubricate
the
bearings
with light engine oil to
prevent
rusting.
Tunr
the lubricated
bearings slowly
through
your
fingeís
to feel for roughness and excessive
play.
Wash the transmission, clutch and transmission cas;e
with
cleaning
solvent and blow dry.
Inspect the case
Íor cracks or burrs which
might hinder the
proper
seating
of
a snap
ring. Dress oÍf
any burrs
with a ilne
cut file.
Clean
the
gears
thoroughly
and
replace
any
that
are worn or
damaged.
Check the bushings in the
case Íor
excessive
wear.
Check
the
synchronizer
cones for
wear
or looseness
in the clutches. lÍ the cones are damaged in
any
way
it
will be necessary
to renew the clutch
assembly and
ri ngs.
2 Insert
the countershaÍt
through the top opening of
the
gearbox
case and
position
it with
the f ront
bearing in its recess.
3
Turn the case
on
its front end with the front end oÍ the
countershaft resting on a
wooden
block and drift
on
the rear
bearing.
4
Install the
1st
speed
gear
on the countershaÍt and fit
a new nut finger tight.
5
Enter the
mainshaft,
partly
assembled
as detailed
in
the
previous
Section,
in the rear opening of the
gear
case
and
complete the assembly in the following
order
(see
FIG 6
: 10).
2nd
speed
gear
with
the
plain
side
to
bearing,
2nd and 3rd synchronizer
and hub.
3rd speed
gear
and
bushing.
4th
speed
cone and svnchronizer.
6 Push the
mainshaft
assembly
towards the front of the
geaÍ
case to engage
the intermediate bearing in its
boss in the case.
Fit
a
new nut to the Íront oÍ the
main-
shaft
and tighten fingeÍ tight.
7 Install the 1st/reverse
sliding
gear
on the rear end of
the main
shaft.
B
Engage
and
hold in two
gears,
1st
Tighten the
nut
on the rear end of
and
torque load to
45 to 50 lb Ít.
P404
ano syncnronrzer
and 2nd speeds.
the countershaft
Lock the nut by
t,
FIG
6
:9 The mainshaÍt
showing the stop
pin
c. Dis-
mantled Írom
the shaft
is
the
2nd
speed
gear
flanged
bushing, the intermediate
ballbearing and the 1st speed
svnchronizer
FIG 6 :10
Key to Fig 6:10 a 2nd speed
gear
b 2ndl3rd speed
synchronizer and hub
c 3rd
speed synchronizer
gear
and
bushing d
4th
speed synchronizer cone
e
4th
speed
syn
ch
ro n I
zer
FIG 6:11 Checking the clearance between 2nd speed
gear
and
bushing
flange, and between 3rd and 4th speed
gears.
The special tool 3A is used to retain 1st speed
gear
In engagement
FIG 6 :1
2 Fitting
the special
gauge
3B
55
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