45
Spacer
Bearing
1st Gear Driven
Spacer
Spline
Shaft
Hi-Low Gear
Bevel Pinion
Shaft
Double
Bearing
Circlip
6. Hold the 1st & 2nd driving gear with one
hand & with other hand pull out the
counter shaft out of the transmission case.
Remove the 1st & 2nd driving cluster gear
with shims & rear spacer from the
transmission.
7. Remove the bearings from retainer, mid
wall of transmission & rear wall of the
transmission. To remove the retainer
bearing & rear transmission bearing first
remove the circlip form the transmission.
8. Clean all the part with the help of cleaning
fluid & inspect all the part for wear &
damage, replace with new one if found.
Note: Always use new Oil seals & circlips at the
time of assembly
Dismantling of Spline Shaft Assembly
(Driven Shaft Assembly)
Dismantling of Counter Shaft Assembly
(Driving Shaft Assembly)
1. Remove the 3 nos of bolts & washer of
Counter shaft retainer with the help of 8
no. spanner.
2. Remove the retainer with oil seal by tapping
the retainer with mallet.
3. Remove the rear circlip on the counter shaft
with the help of circlip plier.
4. Slightly tap the counter shaft from the rear
end with the help of mallet.
5. Hold the Hi low Reverse cluster gear with
one hand & with other pull out the counter
shaft from front side till the Hi low reverse
cluster gear is free to come out from the
transmission case. Also, remove the spacer
which is at the front & rear end of the cluster
gear. The cluster gear has 3 nos of needle
roller bearing & 2 nos of plastic bush inside
it.
Mounting
Bolt
Retainer
Bearing
Hi-Low & Reverse
Cluster Gear
Counter
Shaft
2nd & 3rd Driving
Cluster Gear
Spacer
Spacer
Bearing
2nd & 3rd
Driving Cluster
Gear
Counter
Shaft
Bearing
Hi-Low &
Reverse Cluster
Gear
Counter Shaft
Retainer
Counter Shaft Retainer
Bearing
Spacer
2nd & 3rd
Gear Driven
Transmission
