Before assembling the gearbox make sure that a thorough
inspection of all components is carried out. Remember that
although a failed component may be easy to identify, the
cause of that failure may be less easy to trace. It is also
possible that a failed component may have caused damage
to other areas of the gearbox.
1
Carefully remove all traces of gasket compound from
components as follows:
a
Front and rear casing mating faces.
b
Front casing and torque converter housing mating
faces.
2
Clean t he insid e of t he c asings using a suit ab le
degreasing agent.
3
Carefully inspect all gears, bearing and shafts for signs
of excessive wear or damage. If wear or damage is
evident, components must be renewed.
4
Make sure that all oil way cross drillings in the casings,
shafts and gears are clear and free from debris. Blocked
oil ways are a common cause of bearing failure. Use an
air line to blow through cross drillings.
Note:
If failure of the forward/reverse or 4 wheel drive clutch
is suspected see the relevant dismantling and assembly
procedure in this section.
1st/2nd Gear Synchromesh Unit
The 1st/2nd gear synchro unit must be checked for wear
before assembly as follows:
1
Before d ismant ling t he unit b e aw are t hat on re-
assembly, the components must be kept in their original
relationships.
2
Dismantle the unit by removing the cones and rings
A1
,
A2
and
B1
,
B2
. Push off the sleeve
C
taking care to
retrieve the sets of balls
D
, poppets
E
and springs
F
.
3
Inspect the mating faces of cones and rings. The wear
indicator grooves
X
must still be visible. As a further
check, locate the cones and rings together (as shown at
Y
) and measure the clearance between them using
feeler gauges. The clearance should be between 0.5
and 1.9 mm for both
A
and
B
pairs. If either is out side
these limits then the complete synchro unit must be
renewed.
4
Inspect the teeth on all cones and rings for excessive
wear or damage. If wear or damage is evident the unit
must be renewed.
111 - 2
Section F
9803/3280
Section F
111 - 2
Issue 1
Synchro Shuttle Gearbox
Inspection