61 - 6
Assembly (Cont'd)
28 Temporarily refit taper plug 67.
29 Remove short extension from adaptor.
30 Fit the rear output yoke 15 and attachment bolt 13.
Torque tighten to 350 Nm (258.2 lbf ft).
31 Fit the output yoke adaptor J and secure with bolts K.
Torque tighten to 22 Nm (16.2 lbf ft). Screw the adaptor
C into the yoke adaptor extension L until tight.
32 Fit the lever arm pegs D into the adaptor annular space.
Position the lever unit mounting blocks E in the
appropriate position on the base plate A and secure
with bolts F. Tighten the bolts.
33 Fit a magnetic base DTI G onto the base plate with the
pin resting on the top of the adaptor.
34 Measure the output shaft end float and determine shim
thickness by repeating steps 19 and 20. Refer to view
Y.
35 Remove the lever unit, adaptor, base plate and output
yoke adaptor.
36 Remove the attachment bolt 13 and output yoke 15.
37 Remove oil inlet adaptor 65 and sealing washer 66 from
the rear casing.
38 Turn the gearbox into the horizontal position.
39 Clean the mounting face of the flywheel housing. Mount
the DTI on the face with the probe resting on the end of
the reverser unit shaft. Firmly press the reverser unit
shaft in to take up any shaft end float. Zero the DTI.
Refer to view Z.
40 Screw a threaded bolt or rod into the threads exposed
when oil inlet adaptor 65 was removed, until it touches
the end of the reverser unit shaft.
41 Screw bolt or rod in further (approx. 10 Nm; 7.4 lbf ft)
whilst turning output shaft. Stop when increasing
resistance is felt. DO NOT overtighten. Take the DTI
reading.
42 Calculate the required shim thickness as detailed in
step 20.
43 Remove bolt or rod and the DTI. Temporarily refit oil
inlet adaptor 65 and sealing washer 66.
44 Turn the gearbox into the vertical position, with the rear
casing upwards.
45 Screw a lifting eye into a layshaft end cover bolt hole.
Using a suitable hoist, lift the rear casing 37 away from
the front casing 38. Pry bars may be used at the points
provided to assist in 'cracking' the joint. Turn the rear
casing over.
Section F Transmission
9803/7130
Section F
61 - 6
Issue 1
Syncro Shuttle Gearbox
S204050
S204010
ZZ
YY
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