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General
Inspection of Expendable Parts
D. Synchroniser
Assemblies
1.
Check to ensure all splines are free from excessive
wear.
2.
Check that the engagement dog teeth on the sliding
sleeves, synchroniser rings are free from chipping and
burring.
3.
Check that the synchroniser ring cones are not
excessively worn or showing the effects of overheating.
Check the clearance between the synchroniser ring and
the synchroniser flange is between 1.9 mm maximum
and 0.5 mm minimum.
4.
Renew the springs, plungers and rollers.
E.
Splines
1.
Check splines on all shafts for wear. If synchroniser
hubs, output drive flange or clutch hub have worn into
the sides of the splines, the shafts in this condition must
be renewed.
F.
Thrust Washers
1.
Check surfaces of all thrust washers. Washers
scored or reduced in thickness should be renewed.
G. Reverse Idler Gear
1.
Check bearings and shaft for wear from action of
roller bearings.
H. Clutch Release Parts
1.
Check clutch release parts, yokes and bearing car-
rier. Check pedal shafts. Renew worn shafts and bear-
ings.
I.
Gear Selector Shaft Assembly
1.
Check forks and keys for wear at contact points.
Renew worn parts.
2.
Check forks for excessive and uneven wear, renew
worn forks.
3.
Check lockscrew in selector block. A lockscrew with
worn taper must be renewed.
4.
Check condition and fit of selector key and inter-
lock key in shift shaft. Worn or damaged keys must be
renewed.
J.
Gear Shift Remove Control
1.
Check spring tension on cross shaft. Renew ten-
sion springs if shaft moves too freely.
2.
If housing is dismantled, check cross shaft and
inner lever and the bearing bushes for wear. Renew
worn parts.
3.
Check all seals and locating journals. Renew worn
parts.
K. Bearing Covers
1. Check covers for wear from thrust. Renew covers
worn or grooved from thrust of bearing outer race.
2. Check bores of covers for wear. Renew those worn
oversize.
L. Oil Return Threads and Seals
1. Check oil seal in front bearing cover for damage and
wear, renew if necessary.
2. Check oil seal in speedometer housing for damage or
wear, renew if necessary. Renew grit shield if worn or
loose on flange.
3. Check oil seal journals for wear and renew if worn or
grooved.
M. O-Rings
1. Renew all O-rings.
Summary of Contents for Roadranger TRSM4106
Page 1: ...Service Manual Fuller Mid Range Transmissions TRSM4106 October 2007...
Page 3: ......
Page 6: ...5 01 Section 2 General...
Page 22: ...5 01 Section 2 General Description...
Page 25: ...5 01 3 1 Section 3 Shifting Controls 6 Speed MK 4...
Page 35: ...5 01 3 11 10 Refit the rubber gaiter and breather...
Page 36: ...5 01 4 1 Section 4 Transmission Overhaul...
Page 88: ......