Specifications

GEARBOX AND DIFFERENTIAL ASSEMBLY
and 1st motion shaft bearings as a precaution.
Now at this stage the mainshaft bearing can
be fitted into its housing in the sandwich plate
and secured with the correct circlip. For ease
of assembly, press the other bearing on to the
1st motion shaft and loosely position its large
retaining circlip behind the bearing in readiness
for final assembly. This circlip CANNOT be
fitted AFTER this shaft and bearing have been
pressed into the sandwich plate. The sandwich
plate must now be supported in a vice with
the gearbox side facing towards you. Take
hold of the two assemblies, (mainshaft and
1st motion shaft) and whilst holding the two
`in mesh', simultaneously introduce the shafts to
their respective positions `through' the sandwich
plate. That is the mainshaft into its bearing, the
1st motion shaft and bearing into its housing,
securing the 1st motion shaft with the large circlip
behind the bearing.
Now reposition this assembly in the vice,
turning it through 180 degrees such that the
gear clusters are behind the sandwich plate and
facing away from you.
Place the 1st/2nd gear selector fork around
its hub and press the selector shaft through this
fork and into the sandwich plate. Ensure that the
detent grooves are uppermost and then carefully
secure the fork to the shaft with two roll-pins.
The 5th gear selector rod assembly can now
be inserted through the sandwich plate and
the 3rd/4th gear selector fork placed around
its hub.
Engage 2ND GEAR and push the mainshaft
away from you to the full extent of the available
free movement. This will give better access to
i nstall and secure the interlock pin assembly
to the sandwich plate with two cap headed
bolts. Once this is fitted, the mainshaft can
be returned to its correct position up against
the bearing, and the 1st/2nd gear selector rod
returned to the NEUTRAL position. The 3rd/4th
gear selector rod can now be inserted through the
axis of the 5th gear selector assembly, into the
3rd/4th gear selector fork and secured with care
by roll-pins. The 5th gear pawl assembly should
now be attached to the sandwich plate using two
cap-headed bolts, making sure that the slot in
the 3rd/4th gear selector rod located the end of
the pawl.
The 5th gear complete with its hub and
selector fork can now be fitted to the end of
the mainshaft. The selector fork locates on the
end of the 5th gear selector rod assembly. Secure
the gear to the shaft with the 33mm nut, NOTE
LEFT HAND THREAD, and tighten to a torque
of 14kg/m.(100lb/ft.), THEN indent the locking
collar. Insert the small blanking plug into the
hole in the end of the 5th gear selector shaft
assembly, Please ensure that the small holes in
the shaft, blanking plug and selector fork ALL
align with each other BEFORE securing with two
roll-pins.
The other 5th gear can be fitted with the
spacer ring to the end of the 1st motion shaft
and secured by a circlip. Fit the reverse gear
to its shaft with the thick spacer positioned
between the gear and the sandwich plate. The
reverse gear thrust washer must not be fitted, as
it would prevent full engagement of the gear in
this gearbox. Carefully insert this shaft assembly
i nto the hole in the sandwich plate making sure
that the small LOCATING BALL is aligned with
the machined groove in the sandwich plate. Using
a copper faced hammer, drift the shaft fully into
the hole.
The long interlocking pin can now be inserted
i nto position through the reverse gear detent
hole. Fit reverse gear selector fork to shaft, fit
i nto sandwich plate and secure fork to shaft with
roll-pin.
The FOUR detent pins and springs can now
be inserted. and retained using the force-fit
plugs.
The gearbox cluster assembly is now com-
plete and can be checked for correct operation
before final installation into the gearbox casing.
NOTE: This unit must be fitted to the
gearbox casing BEFORE the special end cover
is attached. To re-check clearance of 4th gear to
casing, refer to previous instructions regarding
casing modifications.