The
gearbox
Section G
1
Description
The gearbox has four forward speeds and
reverse
with
synchromesh
on
all forward gears,
the gear lever being directly located in the
selector forks through
the
gearbox
top
cover.
Routine maintenance
The gearbox should
be
checked every 3,000
miles (5,000km) and
topped
up,
if
necessary,
to
keep the oil capacity
at
a constant
0·64
litres
(1·125
pints).
It
is important that this capacity
is kept constant,
for
any appreciable
drop
in
the
level
will
result in poor lubrication and possible
transmission damage.
To ensure the internal components are kept
clean and free from impurities the gearbox oil
should
be
changed every 12,000 miles
(20,000km).
Gearbox removal and installation
To
remove
1 Disconnect battery leads.
2 Remove air cleaner.
3 Disconnect throttle cable at carburettor.
4 Release throttle return spring, slacken
carburettor L.H. fixing
nut
and move return
spring location bracket
towards
engine
to
clear
engine bulkhead.
5 Drain the radiator and disconnect radiator
top
hose.
6 Disconnect heater hose from water valve.
7
Press
in retaining lugs, and remove choke
and heater knobs from the centre console.
8 Unscrew retaining nuts and
disco1111ect
choke and heater control cables from centre
console.
9 Remove gear lever knob.
1
0 Remove
two
No. 8 self tapping screws,
securing rear
of
centre console
to
driveshaft
tunnel, then
lift
centre console, complete
with
gaiter, over gear lever.
11 Release retaining clip,
·remove cap and
lift
gear lever from gearbox
top
cover.
12
Unscrew six No. 8 self tapping screws and
remove engine rear access panel.
13
Unless the vehicle is on a ramp,
jack
the
vehicle
up
and
fit
suitable stands all round
under the chassis.
14
From underneath
the
vehicle disconnect
starter
motor
lead, unscrew
two
i
UNF
bolts
and nuts, complete
with
plain washers and
lockwashers, and remove starter motor.
15
Unscrew clutch cable adjuster, and
withdraw
cable from operating fork and
trunnion
which
should then be removed from
fork and retained.
16
Disconnect speedometer cable
at
gearbox
rear cover.
17
Remove four
1
5
6
UN
F bolts, nuts and
lockwashers and disconnect driveshaft from
gearbox coupling flange.
18
Support the engine under the sump
with
a suitable jack.
19
Remove four
1
5
6
UNF
set screws and self
locking nuts securing gearbox support
to
chassis
mounting bracket.
20
By means
of
the
jack
carefully
lower
engine and gearbox assembly until the gearbox
rear support is clear
of
the
chassis mounting.
21
Unscrew
two
1
5
6
UNC
bolts and six
1
5
6
UNF
nuts, complete
with
lockwashers, and
carefully
withdraw
gearbox assembly from
engine.
To
install
1 Raise gearbox carefully, locate the fixing
studs in engine rear mounting plate and secure
engine and gearbox assemblies together,
with
six
1
5
6
UNF nuts,
two
1
5
6
UNC bolts and
lockwashers tightening
to
a torque
of
1
·66-
2·07kg
m (12-151b
ft).
2 Using the jack under the sump, carefully
raise engine and gearbox assembly, line
up
·
gearbox support
with
chassis mounting bracket
and secure
with
four
1
5
6
UNF
set screws and
lockwashers
to
a torque
of
2·07-2-49kg
m
(15-181b
ft).
3 Reconnect driveshaft
to
gearbox coupling
flange securing
with
four
1
5
6
UN F bolts, nuts
and lockwashers tightening
to
a torque
of
3·46-4·15kg
m (25-301b
ft).
4 Reconnect speedometer cable at gearbox
rear cover.
5
Secure starter motor
to
gearbox and engine
rear mounting plate
with
two~
UNF
bolts,
nuts, lockwashers and plain washers.
6 Reconnect starter motor lead.
7 Locate .trunnion
in
clutch operating arm,
insert clutch cable and
fit
adjuster.
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