70mm Brazil Passenger

1. Press shielded ball bearing onto clutch gear shaft with snap ring groove facing up, then install snap ring on clutch gear hub.




2. Load 15 pilot roller bearings into clutch gear cavity. Use heavy grease to retain them in place.




3. Install clutch gear to mainshaft, then install detent lever to shifter shaft with roll in and slide 1-2 shifter fork on shaft so its arm engages detent lever.







4. Assemble 3-4 shifter fork onto detent bushing, then slide assembly onto shifter shaft, with 3-4 shifter fork arm located below 1-2 shifter fork arm.

5. Place bellhousing on wooden blocks, Place a thrust washer over hole for countergear shaft. Ensure that thrust washers are located in holes provided in bellhousing.

6. With both synchronizers in neutral, align shifter shaft assembly to mainshaft assembly, indexing shifter forks into synchronizer sleeve grooves.




7. Mesh countergears with mainshaft gears and install countergear, mainshaft and shifter shaft onto bellhousing as a complete assembly.




8. With bellhousing positioned on its side, install snap ring onto ball bearing on clutch gear.

9. Install gasket and bearing retainer onto bellhousing. Use sealer on the 4 retaining bolts. Reposition bellhousing on wooden blocks. Ensure that drain hole in retainer is aligned with hole at end of countershaft.




10. If removed, install reverse lever into case and install snap ring. When reverse lever is installed, screwdriver slot should be parallel with front of case.

11. Install roller bearing into countergear opening with snap ring groove inside of case. Snap ring will be assembled to roller bearing.

12. Place gasket on bellhousing and use sealer to retain it in place. Before installing case, ensure that synchronizers are in neutral position, detent bushing slot is facing outward and reverse lever is flush with inside wall of case.

13. While installing case over mainshaft, countergear and shifter shaft, expand snap ring in mainshaft bearing and allow snap ring to pilot over mainshaft. It may be necessary to tap case using a plastic hammer to aid assembly.




14. Install interlock pin to hold detent bushing in place on shifter shaft, then install idler shaft so that it engages reverse lever within case.

15. Install cover over reverse shifter shaft to retain reverse lever in place, then install detent ball, spring and cap.




16. Install large reverse gear with chamfer on gear teeth upward, then push reverse gear onto mainshaft splines and retain with snap ring.

17. Install small reverse gear with chamfer on gear teeth upward onto countershaft, with shoulder resting against countergear bearing and retain with snap ring.

18. If removed, install snap ring, thrust washer and reverse idler gear with chamfer on gear teeth facing downward onto idler shaft. Retain thrust washer with snap ring.

19. Install snap rings onto shifter shaft.

20. Position speedometer gear retainer in hole in mainshaft with retainer loop forward and slide speedometer gear over mainshaft and into place.




21. Position extension housing and gasket on case, then install 2 pilot bolts followed by 3 regular bolts. Pilot bolts are partially threaded and are installed in top right hand corner and bottom left hand corner of case.




22. Install shifter shaft lever onto shifter shaft, aligning drilled hole near end of shaft. Drive roll pin into shifter shaft lever and shifter shaft.




23. Install 2 bellhousing retaining pilot bolts followed by 4 regular bolts. Pilot bolts are partially threaded and are installed in the right hand top corner and left hand bottom corner of bellhousing.