Preparing the input shaft.

PREPARING THE INPUT SHAFT.

Replace the bearings : Fig. II.

Remove the bearing (2) using extractor [C].

Fit the bearing (2) using a tube 36 mm i.d. × 42 mm o.d. × 200 mm long.

4 speed gearbox : Fig. I.

Remove the bolt by gripping the shaft in a vice fitted with soft jaws.

Fit the bearing (1) (without its circlips) and with groove (a) facing towards the outer end of the shaft.

Tighten the bolt to a torque of 14 m.daN (140 Nm 104 lbf ft).

PREPARING THE OUTPUT SHAFT.

Dismantling the output shaft.

4 speed gearbox : Fig. III

Grip the output shaft in a vice fitted with soft jaws, across the first speed gear (4) which is locked to the shaft by sliding gear (5).

Unlock and remove nut (3).

WARNING : It has a left hand thread

Use a 36 mm open ended spanner.

Remove bearing (6).

Remove : Fig. IV.

• the 4th speed gear (7), and its bush (8),
• the 4th speed baulk ring (9).

If the synchroniser assemblies are to be re-used keep the baulk rings with their respective gears.

• the 3rd-4th synchroniser hub assembly (10),
• the 3rd speed baulk ring (11),
• the 3rd speed gear (12).

Remove : Fig. V

• retaining ring
• retaining ring (14),
• the thrust washers (13).

Remove : Fig. VI

• the 2nd speed gear (15),
• the 2nd speed baulk ring (16).