British Leyland Triumph Toledo, Repair Manual, Page: 135 / 339

SYNCHROMESH GEARBOX
21. Tilt the mainshaft and remove it from the gearbox.
22. Remove the 3rd/top synchro unit.
23. Remove the 3rd gear baulk ring.
24. From the rear of the mainshaft, remove the thrust
washer.
25. Remove the 1st speed gear.
26. Remove the 1st gear baulk ring.
27. **Remove the circlip. Where the third gear mainshaft
thrust washer has three lugs use Tool SI44. Where
the washer has six lugs use Tool SI44A.**
28. Withdraw the washer.
29. Remove the 3rd speed gear and bush.
30. Remove the thrust washer.
31. Remove the 2nd speed gear and bush.
32. Remove the 2nd gear baulk ring.
33. Remove the thrust washer.
34. Remove the lst/2nd synchro unit.
35. Remove the split collars.
36. Lift out the layshaft cluster.
37. Take out the layshaft thrust washers.
38. Remove the reverse idler gear.
39. Unscrew the nut.
40. Remove the reverse actuator and pivot pin.
★ ★
V C
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39.43
MT0598
Reassembling
41. Screw the pivot pin into the reverse actuator until
one full thread protrudes through the lever boss.
42. Fit the actuator and pivot pin into the gear casing
43. Fit the plain washer and tighten the nut.
44. Smear the front face of the layshaft front thrust
washer with grease and stick it in position in the
gear casing. Insert the end of the layshaft spindle
through the casing to centralize the washer.
45. Lower the layshaft cluster assembly into the gear­
box.
46. Fit the rear thrust washer in position.
47. Insert the layshaft spindle and eject the needle-
roller retaining tube.
48. Measure the layshaft cluster end-float. Adjust the
layshaft end-float to 0*18 to 0-33 mm (0-007 to
0-013 in), by selective use of thrust washers, repeat­
ing 44 to 48 as necessary. Do not remove metal
from the bronze face of the thrust washers.
49. Insert the needle-roller retaining tube, eject the
layshaft spindle and allow the cluster to drop to the
bottom of the gearbox.
37.20.04 Sheet 2
Triumph Toledo Manual. Part N o. 545168. Issue 2