The gearbox Section G
8
If
applicable, remove stands and carefully
jack
down
the vehicle.
9 Refit engine rear access panel
to
engine
bulkhead and secure
with
six self tapping
screws.
10
Locate gear lever in selector forks through
gearbox
top
cover and retain in position
with
cap and clip.
11
Lower centre console over gear lever and
secure
to
driveshaft tunnel
with
two
No. 8
self tapping screws.
12
Replace gear lever knob.
13
Reconnect heater and choke control cables
to
centre console, fixing in position
with
chrome
retaining nut.
Replace choke and heater knobs.
14
Reconnect heater hose
to
water valve.
15
Reconnect radiator
top
hose.
16
Move
throttle return spring location
bracket towards engine bulkhead, retighten L.H.
carburettor fixing
nut
and hook return spring
onto
bracket.
17
Replace air cleaner.
18
Refill the radiator.
19
Reconnect battery leads.
20
Readjust clutch.
Dismantling the gearbox
1 Drain gearbox oil.
2 Remove clutch fork and lever assembly
(see
Section
H).
3 Unscrew eight set screws, complete
with
lockwashers and remove
top
cover gasket,
selector springs and balls.
4 Remove seven nuts and lockwashers and
withdraw
front cover. Remove gasket.
5 Using a
suitable drift, tap
out
the mills pins
from
3rd/4th
selector
fork
and lever and then
withdraw
selector shaft through bell housing.
Remove
selector lever.
6 Repeat operation for
1st/2nd
selector fork,
and lever and
withdraw
selector shaft taking
note
of
the interlock pin in the end
of
the shaft.
7 Tap
out
mills pin from reverse selector
lever, and
withdraw
selector shaft through bell
housing.
8 Lift
out
selector forks and
tilt
gearbox to
remove
interlocking balls from cross drilling in
bell housing end
of
selector shaft bores.
9
Withdraw
layshaft
into
bell housing,
allowing
lay gear assembly
to
drop
into
base
of
gearbox.
10
Unscrew six
-l
UNC
set screws, complete
with
lockwashers, and
withdraw
rear cover and
mainshaft
assembly, taking care
not
to
displace
front
or rear synchro sleeves. Remove gearbox
mounting and earth strap.
3
11
Tap
out
primary gear shaft
into
bell housing
noting location
of
needle roller pilot bearing.
12
Lift
out
laygear assembly and the
two
thrust
washers.
13
Withdraw
reverse gear shaft through rear
of
gearbox and
lift
out
reverse gear.
14
Secure rear cover
including
mainshaft
assembly in a vice, release tab washer, unscrew
~
UNF
nut
and remove
tab
washer and coupling
flange from mainshaft.
15
Remove rear cover from mainshaft
assembly.
Mainshaft assembly
To
dismantle
1 Remove 1st speed gear, bush and bush
key,
complete
with
baulk ring from mainshaft.
2 Remove
1st/2nd
gear selector sleeve.
Note:
It
is advisable
to
carry
out
this operation
with
the sleeve wrapped in a suitable piece
of
cloth
to
avoid losing any
of
the three sets of·
balls,
block
springs and plungers from the
synchro body.
3 After removing
sleeve recover balls and
blocks, etc. from cloth.
4 Repeat operation for
3rd/4th
selector sleeve.
5 Remove circlip from spigot end
of
mainshaft.
6 Using a press
tool
press
3rd/4th
synchro
body
from mainshaft.
7
Withdraw
1st speed gear bush key, press
1st/2nd
synchrobody from mainshaft and
remove 2nd speed baulk ring.
8 Remove
2nd/3rd
speed gear from mainshaft.
9 Examine
all mainshaft components
for
wear
and renew
if
necessary
for
subsequent
reassembly.
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