Reliant Rebel 700 1967, Workshop Manual

Page: 42 / 116

Page 42
Gearbox removal and replacement (Figure 1)
To remove
1. Disconnect battery leads.
2. Remove gear lever gaiter.
3. Jack up the vehicle and place securely on axle stands.
4. Drain gearbox oil.
5. Disconnect speedometer cable.
6. Unscrew rear gearbox mounting bolt and remove rear cross
member, noting position of earth braid.
7. Disconnect clutch rod from pedal lever and clutch operating
fork.
8. Disconnect starter motor cable, unscrew two 3/8”UNF nuts,
lock washers and bolts and remove starter motor (might
need to remove oil filter for access).
9. Remove stabiliser rod.
10. Disconnect prop shaft from rear axle (4 x 5/16”UNF nuts,
lock washers and bolts) and withdraw from gearbox.
11. Remove 2 x 5/16”UNC bolts and 6 x 5/16”UNF nuts
complete with lock washers holding gearbox to rear of
engine.
12. Support the gearbox and slide it rearwards from the engine.
To re-install
1. Raise the gearbox to the engine, slide forwards and locate
on the six studs and secure the two assemblies together
using the 2 x 5/16”UNC bolts and the 6 x 5/16”UNF nuts
complete with lock washers.
2. Slide the prop shaft sleeve yoke into the rear of the gearbox
engaging on the splines and secure the rear to the axle
flange with 4 x 5/16”UNF nuts, bolts and lock washers.
3. Refit the stabiliser bar taking care to correctly locate the
grommet in the rear engine plate.
4. Refit the starter motor using 2 x 3/8”UNF nuts, bolts and
lock washers. Re-connect the starter motor cable.
5. Reconnect the clutch rod to clutch operating fork and pedal
lever.
6. Using 8 x 5/16”UNF set screws and nuts secure the rear
cross member to the chassis.
7. Fit the gearbox mounting bolt and reconnect the earth
braid.
8. Reconnect speedometer drive cable.
9. Refill the gearbox with the recommended oil.
10. Adjust the clutch.
11. Remove the stands and lower the vehicle.
12. Reconnect the battery.
Gearbox dismantling (removed from vehicle)
To separate extension and remote control assembly from gearbox.
1. Unscrew 8 x set screws, complete with lock washers,
securing top cover to gearbox. Remove the dip stick (if
fitted).
2. Remove single set screw, and lock washer securing remote
housing to support bracket extension.
3. Carefully lift the remote control assembly from the
extension housing complete with top cover gasket (
Figure
1
).
4. Unscrew 6 x ¼”UNF hexagon nuts and carefully separate
the extension from the main gearbox body.
To dismantle the gearbox
1. Unscrew the drain plug and drain the oil from the gearbox.
2. Remove the rubber gaiter from the bell housing and detach
from the operating fork.
3. Unscrew the nut and bolt securing the operating fork to its
bracket and withdraw the fork from the bell housing.
4. Remove 7 x ¼”UNF nuts and lock washers and detach the
front cover from the gearbox, complete with its gasket.
5. Remove the three selector detent springs and invert the
gearbox carefully to allow the balls to drop out.
6. Using an Allen key, remove the 4 x 5/16”UNF cone screws
from the selector forks and levers.
7. Standing the gearbox on the bell housing, release locking
plate, unscrew the 7/16”UNF bolt and remove locking plate,
washer and coupling flange from the mainshaft. If
necessary, use a suitable extractor to detach the coupling
flange from the mainshaft.
8. Turning the gearbox on to its base and using a round drift of
suitable diameter, tap the reverse gear selector shaft in to
the bell housing and remove it. Withdraw the reverse forks.
9. Rocking the gearbox on to its left-hand side will allow the
interlock ball bearing to roll out.
10. Using a suitable drift, remove the 3
rd
/4
th
selector shaft by
tapping it in to the bell housing. Remove the fork lever.
11. Rocking the gearbox to its right-hand side will allow the
interlock ball bearing to roll out.