Active Vocabulary

TEXT 5

REASSEMBLY

Make sure all components are spotlessly clean. Make sure the top cover is assembled, complete. Reassemble it in a reverse sequence to its disassembly. Reassemble the two synchronic hubs. For the 1st / 2nd unit fit the recessed inner of the hub facing towards the 2nd speed sliding gear. Fit the two springs correctly. If original parts are fitted match up the two marks. Fit the two springs, positioning each one correctly with the three keys in their recesses. Fit the sliding gear with the groove facing the inner part of the hub with the biggest offset. Put the gear casing on its end; bell-housing end down. Fit the secondary / pinion shelf gear cluster into the casing. Now fit to 4th gear and ring its split needle roller cage. Hold the cage halves in light grease. Fit the gear sleeve thrust washer and 4th speed gear. Screw in the bearing adjusting ring nut. Turn the gearbox onto its lower side. Insert the 1st / 2nd and 3rd / 4th selector forks. Insert the reverse gear and its shaft. Punch its roll pins but not too far. Put in the primary shaft, pushing the reverse gear up and down its shaft to allow it to fit. Punch the reverse gear shaft roll pins home. Refit the rear end plate of the primary shaft and lock it. Insert the pinion shaft gently through the gear cluster. Once inserted tap the taper-roller bearing fitted onto the shaft at the other end, select two speeds and lock the gearbox. Refit the speedometer skew gear. Tighten fully. Select neutral. The secondary shaft must now revolve easily and without play. If not something has gone wrong. To rectify, unlock the secondary shaft adjusting ring nut and loosen or tighten appropriately. Then relock. If new bearings have been fitted, a preload on the secondary shaft of 1 to 3.05. lbs will indicate correct fitment. Use a spring balance round the 3rd / 4th groove. Now refit the selector shafts in the exact reverse order:

- 1st / 2nd selector shaft and roll pin;

- 3rd / 4th selector shaft and roll pin;

- locking disc between the selector shafts.

Drop the three locking balls above the selector shafts through the edge of the casing. Follow here with the springs and the 1st / 2nd spring plunger. Use a new gasket and refit the top cover. Move the end of the selector lever (longest finger) in the top cover towards its nearest corner and, having used some gasket cement on both the casing and the cover, place the gasket on the casing and tighten the top cover. If it does not go on easily take it oft and slide the reverse gear along so that it rests on the 4th gear on the primary shafts. Make sure the gearbox is neutral. Try again; theselector lever should side into its correct notch.

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