Preparing the input shaft. (page 2 of 4)

• Remove : Fig. I
• the circlip (1) using pliers F 8.316 B.

Remove : Fig. II.

• The 1st-2nd speed synchroniser hub assembly (2).
• The baulk ring (3).
• The 1st speed gear (4).

Replace the bearing : Fig. III.

Remove the circlip at (a), using pliers F 8.0316 B.

Remove the bearing (5) using extractor C (Place one contact washer at (c) to protect the pastic end).

The bearing areas for the various gears on the output shaft must be absolutely free from defect. Under no circumstances are these areas to be refaced by any means whatsoever. The output shaft must be fitted with its two plastic ends (6).

Fit the bearing (5) on the press using the tube 42 mm i.d. x 48 mm o.d. 280 mm long and fit the circlip at (a) : Fig. II.

Place the pointed ends of the circlips on the opposite side to their respective components to facilitate their removal, at a later date, if necessary.

Oil the gear bearing areas and the baulk rings with gearbox oil before fitting them.

Fit : Fig. II

• the 1st speed gear (4),
• the baulk ring (3),
• the 1st-2nd speed synchroniser hub assembly (2) (with groove (b) towards the 1st speed gear).

Assembling a ball type synchroniser : Fig. IV.

Place the three springs (8) and the three pads (9) in the hub (7).

Place this assembly against the sliding sleeve (11). (The flat face of the hub (7) is to be towards the groove on the sliding gear (11). Fit the three ball (10).

Measure the 1st-2nd speed synchroniser hub end float Fig. I and V.

Select, from the circlips thicknesses available (1) one that will provide a maximum end float of 0.05 mm.

It should not be possible to insert a 0.05 mm feeler gauge between the retaining ring (1) and the side wall of the groove.

Repeat these operations to determine the thickness of the 2nd and 3rd speed gear thrust washers (maximum clearance 0.05 mm).

Fit : Fig. VI

• the 2nd speed baulk ring (12),
• the 2nd speed gear (13).