60512
FIG.
8.11111
INSTALLING THE SYNCHROMESH
UNIT ENGAGEMENT RING
(62)
D.
Teeth in relief;
V.
Flat spring
holder
seat;
58.
Synchromesh cone; 59. Fixed sleeve;
63.
2nd
and 5th forward driven gear
Arrange in the
housing
the
front
ball bearing
(Item
37)
with
its
retaining ring,
then
fit
the
end cap securing it
with
two
nuts
only.
Set the
transmission
housing
upright
with
the back end uppermost.
Arrange,
inside
the housing,
the
1st-4th
speed driven gears (Item
38,
Fig.
8.1117)
and
1st-2nd reverse
ones
(Item 39) as illustrated
in Fig.
8.11/10,
the
synchromesh
unit
(Item
A)
and the thrust washer (Item
43)
with
the
outer
chamfer
oriented as shown in Fig. 17.
Install the rear ball bearing (Item 44, Fig.
8.11/7)
on the shaft, heating
it
in
oil
at
176°·194°F. (80°·90°C.).
Introduce
the driven
shaft, complete.
Turn the
housing
back horizontal, remove the
front
cap and
tighten
the
nut
(Item
Cu,
Fig.
8.11110).
3.
Place the
transfer
gear (Item
40)
as shown in
the
detail
(b),
then
fit
the reverse gear shaft
(Item
41).
4.
Place
the
2nd-5th and 3rd-6th speed
shifter
fork
(Item 65)
complete
with
dowel
and
fit
the
shifter
bar (Item 64)
with
the
end
threaded
hole
facing back (Fig.
8.11113).
5.
Install the driving
shaft
(Item 27, Fig.
8.1117),
as follows:
Install the rear ball bearing (Item
35)
in the
housing
using a driver.
FIG.
8.11112
INSTALLING THE SYNCHROMESH
UNIT FLAT SPRINGS
(60)
d. Speed gear disengagement safety teeth;
R.
Central
relief
on spring
holder
(61);
58.
Syn-
chromesh
cone; 59. Fixed collar; 61. Flat
spring
(60) holder; 62.
Sliding
ring
Install on the shaft the front ball bearing
(Item 28)
with
thrust
ring after heating it in
oil
at 176°·194°F. (80°·90°C) and the oil shield
(Item 29) as
shown
in Fig.
8.11/7
and
lock
them in place
with
their
retaining ring.
Place the 1st-4th forward and 1st-2nd reverse
driving gear (Item 30, Fig.
8.1117)
over the
shaft.
Install
the
complete
shaft from the
front
end,
insert
from the inside
of
the hous-
ing the 2nd-5th and 3rd-6th speed drivi'ng
gear (Item 31)
complete
with
thrust washer
(Item
32)
and
its
retaining (Item
33)
and, final-
ly,
the
end
ring
(Item
34).
Install
the
front
cap (Item
26)
complete
with
outer
and
inner
seals. Install the rear ball
,bearing (Item
35)
with
the aid
of
a drive bar
(Fig.
8.11/13)
and
check
the 2nd-5th and 3rd-
6th
driving
gear (Item
31,
Fig.
8.1117)
for free
rotation
by hand
without
end play.
6.
Assemble
the
auxiliary planetary gear reduc-
tion
unit
on
the
work bench, as follows:
Place the driven gears (Item
53,
Fig.
8.1119)
on
the
carrier (Item
54)
lubricating
with
Multi-
Purpose Grease the 18 rolling needles (Item
51)
to
place
them
inside
the
hub
of
each gear.
Lock
punch
the
flat-head screws
attaching
the
driven gear
shaft
retaining
disc
(Item
55)
at
two
diametrically
opposed
points
along
the
screw head
slot.
7.
Install
the
planetary gear unit after
installing
the
inside
thrust
washer (Item
45)
with
the oil
Power Train ·
75
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