Power transmissionLayshaft: dismantling and assembling
| Layshaft: dismantling and assembling |
| Special tools and workshop equipment required |
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| Gearbox extractor set -U-40100- |
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| Gearbox repair set -U-40200- |
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| Circlip opening pliers -A-81124- |
Note!
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| Whenever new gears or a new layshaft are fitted consult the technical data → Chapter, Code letters, group numbers, ratios, filling quantities |
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| If the layshaft or the roller bearings are replaced, the layshaft must be adjusted → Chapter |
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| The layshaft must be adjusted whenever elements have been replaced which could affect the position of the roller bearings. Refer to Adjustment chart → Chapter |
| 2 - | Outer track, roller bearing |
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| Remove together with 1st gear → Fig. |
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| Installation position → Fig. |
| 6 - | Needle roller bearing |
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| For the sliding 1st gear |
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| Inner ring for 1st gear |
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| Theck that the tabs show no signs of wear |
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| Installation position → Fig. |
| 8 - | Outer ring for 1st gear |
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| Fit it to the 1st gear syncromesh ring, item → Item |
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| Installation position → Fig. |
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| Replace if it shows signs of wear or grooves |
| 9 - | Syncromesh ring 1st gear |
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| On fitting, the tabs on the ring must fit into their housings in the syncromesh assembly for 1st and 2nd gear → Item |
| 11 - | Syncromesh assembly for 1st and 2nd gear |
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| They are matching pairs |
| 17 - | Syncromesh ring 2nd gear |
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| Installation position → Fig. |
| 18 - | Outer ring for 2nd gear |
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| Fit to syncromesh ring → Item |
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| Installation position → Fig. |
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| Replace if it shows signs of wear or grooves |
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| Inner ring for 2nd gear |
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| Check that the tabs show no signs of wear |
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| Installation position → Fig. |
| 22 - | Needle roller bearing |
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| Assembly position: the identification groove should face the cone |
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| Check that the ratio (number of teeth) is correct → Chapter |
| 29 - | Outer track, roller bearing |
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| The step of the shim should be facing the roller bearing |
| 34 - | Needle bearing for gear, 5th gear |
| 36 - | Syncromesh ring 5th gear |
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| Fit onto the 5th gear syncromesh ring |
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| Replace if it shows signs of wear |
| 38 - | Syncromesh hub 5th gear |
| 39 - | Sliding sleeve 5th gear |
| Remove the outer track of the roller bearing |
Note! | Between the outer track of the roller bearing and the gearbox casing a 1 mm thick washer is fitted. |
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| Fit the outer track of the roller bearing |
Note! | Between the outer track of the roller bearing and the gearbox casing fit first the 1 mm thick washer. |
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| Remove the roller bearing together with the 1st gear |
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| Locate tool -U-40100/3- under the first gear. |
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Warning | Be careful when releasing the circlip as it could sping out and case harm. |
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| Removing the 1st and 2nd gear syncromesh assembly |
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| After removing the circlip, remove the 2nd gear and the syncromesh assembly as a unit. |
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| Locate tool -U-40100/3- under the 2nd gear. |
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| Removing the roller bearing |
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| Locate tool -U-40100/4- under the bearing. |
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| Locate tool -U-40200/4- over the layshaft and remove the bearing. |
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| Fitting the roller bearing |
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| Locate tool -U-40100/3- under the attack gear. |
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| Place tool -U-40200/19- (side A) over the bearing and secure. |
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| Remove the outer track of the roller bearing |
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| Remove the secondary shaft outer roller bearing track from the clutch housing, with tool -U-40100/2-. |
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| Fit the outer track of the roller bearing |
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Note! | Tool -A-81124- can also be used. |
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| Checking wear on inner ring for 1st and 2nd gear |
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| Before checking for wear, throughly clean the syncromesh rings and their corresponding gears. |
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| Press the syncromesh ring onto the cone of the sliding gear and measure dimension “a” with a feeler gauge. |
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| Ring syncromesh | Measurement “a” on a new syncromesh | Wearlimit |
| 1st and 2nd gears | 0.75...1.25 mm | 0.3 mm |
| Checking wear on syncromesh ring for 1st and 2nd gear |
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| Before checking for wear, throughly clean the syncromesh rings and their corresponding gears. |
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| Press syncromesh gear, external ring and internal ring against the cone of the 2nd sliding gear and check dimensions “a” with a feeler gauge. |
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| Ring syncromesh | Measurement “a” on a new syncromesh | Wearlimit |
1st and 2nd
gears | 1.2...1.8 mm | 0.5 mm |
| Assembly position of external/internal rings and 2nd gear syncromesh |
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| Fit external ring -A- on 2nd gear. |
| The angled tabs -arrow 1- must be facing the external ring -B-. |
| The tabs -arrow 2- must fit into the cut-outs -arrow 3- of the sliding gear. |
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| Fit syncromesh ring -C-. |
| The cut-outs -arrow 4- fit into the angled tabs -arrow 1- of the external ring -A-. |
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| Assembly of 1st and 2nd gear syncromesh components |
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| Fit the sliding sleeve -2- on the syncromesh hub -3- so that the cut-outs of both components coincide. |
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| Insert the locking keys -4- and secure them with springs -1- at 120° from each other. |
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| Assembly of 1st and 2nd gear syncromesh components |
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| The angled ends of the springs must locate in the inner hollow of the corresponding locking keys. |
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| Fitting the syncromesh assembly for 1st and 2nd gears |
| Notch -1- for the jaw on the sliding sleeve should be facing 1st gear and the toothed part -2- of the sleeve facing 2nd gear. |
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| Turn syncromesh gear so that the cut-outs coincide with the locking keys. |
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| Assembly position of the 1st gear external ring |
| The tabs -arrows- should face the teeth of the reverse gear -A-. |
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| Assembly position of the 1st gear external ring |
| The tabs -1- should fit into the cut-outs -2- of the syncromesh ring -B-. |
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| Fit the needle bearing. |
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| Assembly position of the sliding 1st gear |
| The cut-outs of the collar -arrows- should fit into the tabs of the syncromesh ring → Fig., |
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| Fitting the roller bearing |
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01 Transmission
