Disassembly
CLUTCH HOUSING - TYPE A GEARBOX - REMOVE
1. If installed: remove and discard clips retaining clutch release bearing pads, remove bearing and clutch release lever, recover pads.
2. Remove 2 bolts securing release lever pivot post, remove post.
3. Remove 6 bolts securing clutch housing to gearbox, remove housing.
NOTE: Dowel located.
CLUTCH HOUSING - TYPE B GEARBOX - REMOVE
1. Remove clutch release bearing.
2. Remove bolt securing spring dip to clutch - release lever, remove clip.
3. Remove clutch release lever.
4. Remove "C" clip from release lever pivot post, discard clip.
5. Remove 6 bolts securing clutch housing to gearbox, remove housing.
NOTE: Dowel located.
CLUTCH HOUSING - TYPE C GEARBOX - REMOVE
1. Pull clutch release lever off pivot post, remove lever and clutch release bearing.
2. Remove 6 bolts securing clutch housing to gearbox, remove clutch housing.
NOTE: 2 longest bolts are Fred at dowel locations and have plain washers under their heads.
CLUTCH HOUSING - TYPE D GEARBOX - REMOVE
NOTE:
^ Type D gearboxes have a standard clutch housing adaptor which mates with both V8 and diesel engine clutch housings.
^ The above illustration shows the gearbox removed at the Cutch housing adaptor with the clutch housing adaptor (containing the clutch mechanism) still installed to the engine.
1. Remove 2 bolts securing release lever pivot post. Remove post.
2. Remove 6 bolts securing adaptor housing to gearbox. Remove adaptor housing.
GEAR CHANGE/SELECTOR HOUSINGS - TYPE A GEARBOX - REMOVE
1. Remove 4 bolts securing gear change housing, remove housing.
NOTE: Dowel located.
2. Remove 4 bolts securing transfer box selector housing, remove housing.
REMOTE HOUSING - TYPE A GEARBOX - REMOVE
1. Noting their installed position, 3 bolts securing remote housing, remove housing.
NOTE: Dowel located.
GEAR CHANGE/SELECTOR HOUSINGS - TYPE B GEARBOX - REMOVE
1. Remove 2 Torx screws securing gear change housing cover, remove cover; recover sealing rubber.
2. Remove 4 bolts securing transfer box selector housing, remove housing.
3. Noting their installed position, remove 3 bolts securing gear change housing, remove housing.
NOTE: Dowel located.
SELECTOR QUADRANT - TYPE A GEARBOX - REMOVE
1. Remove and discard set screw securing selector quadrant.
2. Move selector shaft forwards, remove quadrant.
GEAR CHANGE LEVER YOKE - TYPE B GEARBOX - REMOVE
1. Remove and discard set screw securing yoke.
2. Move selector shaft forwards, remove yoke.
REMOTE GEAR CHANGE - TYPE C GEARBOX - REMOVE
1. Noting installed positions of mounting rubbers and washers, remove 2 bolts securing remote gear change to extension housing, recover washers and mounting rubbers.
2. Remove 2 bolts securing remote gear change bracket to extension housing, recover washers and mounting rubbers.
3. Release remote gear change from extension housing, disconnect selector rod from selector shaft pin.
REMOTE GEAR CHANGE - TYPE D GEARBOX - REMOVE
1. Remove 4 bolts securing remote gear change to extension housing.
2. Release remote gear change from extension housing.
GEAR CHANGE LEVER YOKE - TYPE D GEARBOX - REMOVE
1. Remove and discard set screw securing yoke.
2. Move selector shaft forwards.
- Remove yoke.
EXTENSION HOUSING - TYPES A AND B GEARBOX - REMOVE
1. Thread a 12mm bolt into the end of the output shaft and using tool LRT-37-009 and LRT-37-010 withdraw oil seal collar.
2. Remove reverse/5th gear selector spool retainer.
3. Remove 10 bolts securing extension casing noting position of longer bolts.
4. Place a suitable container underneath the box to catch any oil spillage and remove the extension housing.
5. Remove oil filter.
6. Secure center plate to gear casing with 2 bolts 8 x 35 mm.
EXTENSION HOUSING - TYPE C GEARBOX - REMOVE
1. Remove and discard self-locking nut securing selector shah pin to selector shaft; remove pin.
- Carefully pry speedometer pinion housing and gear out of extension housing, remove and discard O-ring.
- Remove 5th gear spool retainer, remove and discard O-ring.
4. Noting their installed position, remove 10 bolts securing extension housing to gearcase.
5. Using a soft faced mallet.
- tap extension housing to free it from locating dowels.
6. Remove extension housing.
NOTE:
^ Speedometer drive gear may be a tight fit on output shaft and this can prevent removal of extension housing.
^ Insert suitable blocks of wood between extension housing and center plate and carefully lever extension housing away until drive gear is released.
7. Remove and discard selector shaft oil seal.
8. Secure center plate to gearcase with 2 bolts 8 x 35mm.
EXTENSION HOUSING - TYPE D GEARBOX - REMOVE
1. Remove reverse gear/5th gear selector spool retainer.
2. Remove 10 bolts securing extension case to main gearcase, noting position of longer bolts.
3. Place a suitable container underneath the box to catch any oil spillage.
4. Using a soft faced mallet, tap extension housing free from its location dowels.
5. Remove extension housing.
6. Remove oil filter.
5TH AND REVERSE GEAR - REMOVE
1. Using a suitable two legged puller remove 5th gear layshaft support bearing Back from the end of layshaft.
2. Using tool LRT-37-023 to hold the 5th layshaft gear, remove the 5th layshaft gear nut.
3. Remove thrust collar segments, retaining ring and segments, drift out the roll pin.
4. Later gearboxes: Remove split washer securing 5th layshaft gear to shaft.
5. Remove 5th layshaft gear.
6. Remove mainshaft rear support bearing race using tools LRT-37-009 and LRT-37-024.
7. Remove 1 2mm bolt from end of mainshaft.
8. Remove mainshaft 5th gear with synchromesh baulk ring.
9. Remove mainshaft 5th gear split needle roller bearing.
10. Remove circlip securing 5th gear synchromesh hub.
11. Rotate selector spool clear of synchro hub fork and remove 5th and reverse synchromesh hub assembly complete with fork and spool.
12. Remove mainshaft reverse gear complete with needle roller bearing and bush noting selectable spacer between reverse gear bush and center plate bearing.
13. Remove layshaft reverse gear.
14. Remove center plate detent plug, spring and ball.
15. Remove 2 bolts securing spool retainer, remove retainer.
16. Remove "slave" bolts.
MAINSHAFT AND LAYSHAFT - REMOVE
1. Align selector shaft pin with slot in center plate and using wooden blocks and hide mallet, drive off center plate.
2. Collect detent ball and spring, remove bearing races and shims.
3. Remove layshaft, mainshaft and selector shah from casing as complete unit.
4. Remove input shaft, and 4th gear baulk ring.
- (If not already removed with mainshaft).
MAINSHAFT - DISMANTLE
1. Using LRT-99-002 and support bars under 1st gear, press mainshaft support bearing from mainshaft.
2. Remove 1st gear, bush needle bearing and synchromesh baulk rings.
3. Remove 1st/2nd gear synchromesh selector hub, 2nd gear synchromesh baulk rings, second gear and needle bearing.
4. Invert mainshaft and using LRT-99 002 and support bars under 3rd gear, press off pilot bearing
5. Remove spacer, 3rd/4th gear synchromesh selector hub, synchromesh baulk rings, 3rd gear and needle bearing.
GEARBOX CASING
Degrease and clean all components. Inspect casing for damage, cracks and stripped threads.
1. Install level plug.
2. Install new copper washer to drain plug.
FRONT COVER - DISMANTLE
1. Remove front cover and remove bearing races.
- Check that spring clips are intact.
2. Remove oil seal from cover.
- DO NOT install new seal at this stage.
CENTER PLATE- DISMANTLE
1. Remove bearing races and shims and check for wear and damage.
2. Inspect for damage and selector rail bore for wear.
3. Remove splash shield if required.
4. Press out reverse idler gear shaft using suitable press and check for wear.
5. Remove idler gear, needle bearing and spacer and check for wear and damage.
6. Check center plate detent balls for wear and springs for distortion, replace as necessary.
7. Check that threads of detent plug are not damaged.
NOTE: Patchlok plug may be re used provided threads are undamaged.
EXTENSION HOUSING - TYPES A AND B GEARBOX - OVERHAUL
1. Examine for damage to threads and machined faces.
NOTE: Types A and B gearbox extension housing shown.
2. Remove three screws and remove oil pump.
3. Remove oil pick-up pipe and check for obstruction.
4. Drift out layshaft support bearing.
5. Remove mainshaft rear oil seal.
6. Drift out mainshaft support bearing and oil pick up ring.
7. Remove shaft retaining reverse inhibition cam.
8. Remove reverse inhibition cam and spring.
9. Remove reverse light switch and sealing washer.
10. Remove gate plate.
11. Check all components for wear and renew as required.
EXTENSION HOUSING OVERHAUL, TYPE C GEARBOX - SAME AS FOR A AND B TYPES AND INCLUDING THE FOLLOWING:
1. Recover speedometer dive gear and spacer.
2. Check speedometer drive gear for wear and damage, renew if necessary.
3. Check speedometer pinion for wear and damage.
- Check that scrolling on shaft is clear; renew pinion and shaft H necessary.
4. Check slots in 5th gear spool guide for wear, renew spool guide if necessary.
TYPE C AND D GEARBOXES
CAUTION:
^ The rear mainshaft oil seal installed to Type C and D extension housings is deferent to Types A and B.
^ When levering out seal, take care not to damage the seal location surfaces.
NOTE: Type D gearbox extension housing shown.
1. Lever out mainshaft oil seal, taking care not to damage the location surfaces