Assembling Gear Carrier

Exploded View:

Description:

Assembling

1. Position lock pin in bore correctly.

2. Insert springs and sleeves for gear interlock (1st through 4th gears).

3. Adjust operating lever.

4. Swing in drive pinion, engaging reverse gear for this purpose.

5. Insert selector fork and selector rod for 1st and 2nd gears, and push in drive pinion fully.

6. Slide in 3rd and 4th gear selector fork positioned correctly on selector rod for 5th and reverse gears.

7. Install input shaft, insert 3rd and 4th gear selector fork in sliding sleeve and push in input shaft completely.

Note: Press roller bearing inner race off of input shaft to make installation easier.

8. Adjust selector rods to neutral position and make sure locks are positioned correctly.

9. Slide in 3rd and 4th gear selector rod with small lock (held in position with grease).

10. Lock 3rd and 4th gear selector fork on selector rod with a pin, holding with a hammer.

11. Lock dog for 1st and 2nd gear selector rod on selector rod with a pin, while holding with a hammer.

12. Install stop bolts with new seals and tighten to specified torque.

13. Clamp 4th gear/drive pinion in a vise.

14. Determine thickness of shim for 5th gear.

Specifications:

Measure distance "a" with a depth gauge and refer to following table for thickness and part number of shim.

15. Heat 5th gear/drive pinion to about 120 °C and install gear with collar facing drive pinion. If necessary, knock on against stop with a suitable mandrel.

16. Tighten bolt for drive pinion to specified torque.

17. Clamp input shaft in a vise that shafts are vertical.

18. Lubricate cylindrical rollers of input shaft bearing with a little grease and press outward.

19. Center input shaft in bearing and slide on inner race of cylindrical roller bearing.

20. Determine thickness of circlip for cylindrical roller bearing inner race. Use and install the thickest possible circlip. Axial play may be max. 0.05 mm.

Specifications:

The following circlips are available.

21. Mount 5th gear with synchronizer and sliding sleeve, needle bearing and selector fork. Lock selector fork on selector rod with a pin, holding with a hammer.

22. Insert circlip for synchronizer.

23. Insert 5th gear synchromesh ring.

24. Heat clutch to about 120°C (250°F) and mount, driving it on against stop with a suitable piece of pipe if necessary.

25. Heat 2nd ball bearing inner race to about 120°C (250°F) and install.

26. Install dowel sleeves, position gasket and mount rear cover.

27. Heat 1st ball bearing inner race to about 120°C (250°F) and install.

28. Tighten bolt for input shaft to specified torque.

29. Tighten cover/gear carrier bolts to specified torque.

30. Press in new end cover.