61 - 7
Assembly (Cont'd)
46 Using a bearing puller, remove the layshaft bearing cup
from the rear casing. Referring to the shim thickness
calculation for the layshaft 52, fit the required shims
into the rear casing. Using a bearing dolly, refit the
layshaft bearing cup.
47 Repeat step 46 for the main shaft 53, output shaft 41
and reverser unit 54.
48 Turn the rear casing over.
49 Fit the face 'O' rings 39 and 40 into the front case
mating face recesses.
50 Apply a bead of sealant to the front case mating face,
smoothing the sealant around the 'O' ring areas.
51 Screw a lifting eye into the layshaft end cover bolt hole
of the rear casing 37. Using a suitable hoist, lift the rear
casing into position over the front casing 38. Carefully
lower the rear case onto the front case, ensuring that
the locating pegs are fully engaged. Secure the casings
with bolts 36. Torque tighten to 56 Nm (41.3 lbf ft).
Remove the lifting eye.
52 Repeat end float measurements, as detailed in steps 15
to 36 inclusive, to check that end float on all shafts
remains within the tolerance of 0.03 to 0.08 mm.
53 If any measurement is outside the tolerance, remove
rear casing, see step 45. Using a bearing puller, remove
the bearing cap(s) of the shaft(s) that is outside the
tolerance. Add or remove shim(s) to bring the
measurement(s) within the tolerance. Using a bearing
dolly, refit the bearing cup(s) into the rear casing.
54 Remove the front case 'O' rings 39 and 40 and clean
the sealant from the front case mating face.
55 Repeat steps 49 to 52 inclusive. The end float
measurements should now be within the tolerance for
all shafts. If any measurement is still outside the
tolerance, repeat step 53.
56 Turn the gearbox into the horizontal position. Fit new
'O' ring 64 to the oil pump assembly. Refit the oil pump
assembly and secure with new washers 62 and bolts
61. Torque tighten to 28 Nm (20.7 lbf ft). Make sure that
the pump rotors rotate.
57 Pack the cavity between the lips of both front and rear
output shaft oil seals 17 with grease and fit the seals.
58 Fit the rear output yoke 15 and front output brake disc
15A and secure with attachment bolts 13. Do not fully
tighten. Align the front and rear output yokes.
59 Fit the gear change turret 19 with a new gasket 20 and
secure with setscrews 18. Torque tighten to 56 Nm
(41.3 lbf ft).
60 Fit oil inlet adaptor 65 with new sealing washer 66 into
the rear casing. Torque tighten to 102 Nm (75.2 lbf ft).
61 Fit taper plug 67. Torque tighten to 56 Nm (41.3 lbf ft).
Section F Transmission
9803/7130
Section F
61 - 7
Issue 1
Syncro Shuttle Gearbox
S203980
S203991
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