Dismantling

Dismantling

1. Remove components, discard conical spring washer and 'O' rings.
2. Check needle bearings for wear and smoothness of rotation.
3. Check gears for wear and chipping of teeth.
4. Check secondary shaft splines for wear and bearing surfaces for damage and wear.
5. Replace components as necessary.

30 N m A
44M 0359

A Locknut

Clearance measurement

Note: Lubricate all parts with transmission fluid during assembly.

1. Remove the secondary shaft bearing from the gearbox housing.
2. Assemble the secondary shaft without 'O' rings. Install the idler gear using a press, then torque the secondary shaft locknut to 30 Nm.

Note: Do not install the 'O' rings or conical spring washer during clearance measurement.

44M 0360

A D.T.I. gauge
B 2nd gear

3. Attach the D.T.I. gauge to 2nd gear as shown.

44M 0361

A D.T.I. gauge
B 2nd gear
C Selective splined washer

4. Measure 2nd gear axial clearance in at least three places while moving 2nd gear. Standard = 0.04 – 0.12 mm
5. If the clearance is incorrect, remove the splined washer and measure the thickness.

Note: Nine thicknesses of splined washer are available rising in increments of 0.05 mm from 4.05 to 4.45 mm thick.

6. Select the appropriate thickness of splined washer and check that the clearance is within tolerance.