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Dismantling and assembling output shaft > < Adjusting input shaft

A2

Exploded view - output shaft
Exploded view - output shaft
  Note
t  Refer to technical data → Chapter when installing new gears or a new output shaft.
t  Following output shaft or taper roller bearing replacement, the output shaft must be re-adjusted → Chapter.
t  Table of adjustments → Chapter
   
1 - Gearbox housing
2 - Washer
q   1 mm thick
3 - Tapered roller bearing outer race
q   Press out of gearbox housing with output shaft
q   Pressing in → Fig.
4 - Tapered roller bearing inner race
q   Press off with 1st speed selector gear → Fig.
q   Pressing on → Fig.
5 - Thrust washer
6 - 1st speed selector gear
q   Installation position → Fig.
7 - Needle bearing
q   For 1st gear
8 - Synchro-ring (inner ring for 1st gear)
q   Checking for wear → Fig.
q   Check lugs for scoring
q   Installation position → Fig.
9 - Outer ring for 1st gear
q   Insert in synchro-ring -Item 10-
q   Installation position → Fig.
q   Renew if scored
10 - 1st gear synchro-ring
q   Checking for wear → Fig.
q   Insert such that recesses engage in locking pieces of locking collar -Item 12-
11 - Circlip
q   Pressing out → Fig.
q   Fitting → Fig.
12 - Locking collar with synchronising hub for 1st and 2nd gear
q   Parts are paired
q   Pressing off → Fig.
q   Assembling locking collar and synchro-hub → Fig. and → Fig.
q   Pressing on → Fig.
13 - Spring
14 - Locking collar
15 - Synchronising hub
16 - Locking piece
q   3x
17 - Spring
18 - 2nd gear synchro-ring
q   Checking for wear → Fig.
q   Installation position → Fig.
19 - Outer ring for 2nd gear
q   Position on synchro-ring -Item 20-
q   Installation position → Fig.
q   Renew if scored
20 - Synchro-ring (inner ring for 2nd gear)
q   Checking for wear → Fig.
q   Check lugs for scoring
q   Installation position → Fig.
21 - 2nd speed selector gear
22 - Circlip
q   Pressing out → Fig.
q   Fitting → Fig.
23 - Needle bearing
q   For 2nd gear
24 - 3rd gear wheel
25 - Circlip
q   Pressing out → Fig.
q   Fitting → Fig.
26 - Circlip
q   Pressing out → Fig.
q   Fitting → Fig.
27 - 4th gear wheel
q   Identification groove points towards final drive splines
28 - Output shaft
q   Dismantling and assembling → Chapter
q   Pay attention to correct ratio (number of teeth) → Chapter
q   Adjusting → Chapter
29 - Tapered roller bearing inner race
q   Pulling off → Fig.
q   Pressing on → Fig.
30 - Tapered roller bearing outer race
q   Removing → Fig.
q   Pressing in → Fig.
31 - Shim
q   For output shaft
q   Table of adjustments → Chapter
32 - Clutch housing
33 - Thrust washer
q   Shoulder on thrust washer faces towards tapered roller bearing
34 - Sleeve for needle bearing
q   Press off with 1st speed selector gear → Fig.
q   Driving on → Anchor
35 - Needle bearing
q   For 5th speed selector gear
36 - 5th speed selector gear
37 - 5th gear synchro-ring
38 - Spring
q   Position on 5th gear synchro-ring
q   Renew if worn
39 - 5th gear synchronising hub
q   Removing → Chapter
40 - 5th gear locking collar
q   Removing → Chapter
41 - Circlip
q   Renew
q   Determining thickness

   

Dismantling and assembling output shaft > < Adjusting input shaft