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5/01
Make sure that interiors of all housings are clean. It is
important that dirt be kept out of transmission during
reassembly. Dirt is abrasive and can damage polished
surfaces of bearings and washers. Use certain precau-
tions, as listed below, during reassembly.
1.
Gaskets
Use new gaskets where detailed only
(neutral detent cover and remote control housing cov-
ers). All other locations ensure mating faces are clean
and undamaged and apply a continuous bead of Loctite
518 Flange Sealant to one face only. Do not apply
excessive sealant or allow it to penetrate into the bear-
ings.
2.
Capscrews
Use thread sealant (Loctite 641) on
all capscrews. The corresponding torque ratings are to
be found in Torque Recommendations for Screws and
Nuts .
3.
O Rings
Lubricate all O rings lightly with sili-
cone lubricant.
4.
Initial Lubrication
Lubricate bearings with
gearbox oil during reassembly.
5.
Axial Clearances
Maintain the end float of
mainshaft gears as detailed in the chart on the following
page.
6.
Bearings
Use of flange-end bearing drivers is
recommended for the installation of bearings. These
drivers apply equal force to both races of the bearing,
preventing damage to balls and races and maintaining
correct bearing alignment with shaft and bore. A tubular
type driver, if used, will apply force only to the inner
race. Heating the bearing inner tracks will aid installa-
tion.
7.
Output Shaft Drive Flange
Tighten the nut to
the correct torque.
8.
Synchroniser Hubs
All synchroniser hubs are
an interference fit on the mainshaft splines and must be
heated to approximately 85¡C (180¡F) before installa-
tion.
1/9
General
Reassembly Precautions
9.
Layshaft
The layshaft gears are a shrink and
press fit on the layshaft body. The gears must be heat-
ed to 150¡C (300¡F) before assembly.
10.
Prior to fitting a flange (or yoke) ensure that the
seal track is not grooved, scored or pitted. If in doubt, it
must be replaced.
11.
All synchroniser flanges are now loctited to the
gears. It is recommended that this is carried out before
reassembly commences to allow sufficient time for the
Loctite to cure.
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: ......