Sunbeam ALPINE I SERIES: APLINE II SERIES, Workshop Manual, Page: 139 / 413

WSM. 12-4
Section E (Gearbox & Overdrive)
REAR COVER
To remove and refit
Remove speedometer pinion and bush.
Remove rear mounting plate (two bolts and one
nut). Remove the remaining two bolts and washers
securing rear cover to casing and remove cover.
Remove paper joint.
Refitting is a reversal of the above instructions.
If the rear bushes are worn or scored, a cover
complete with finished bushes is available. Alterna­
tively, if boring facilities are available, new bushes
may be fitted and bored to 1·380/1·379" (35·05/
35·02 mm) within ·0015" (·038 mm) total indicator
reading at 90 deg. to the front face of the cover.
A strengthened cover with a clrcllp to retain the oil
seal, and a propeller shaft with no dust shield are
fitted to later cars. (To give interchangeability
with the new rear cover, which supersedes the old,
replacement shafts for early or later cars will not
be fitted with a dust shield).
TOOLS FOR
REASSEMBLING
DISMANTLING
GEARBOX
AND
The dismantling and reassembling of the gearbox
will be simplified by the use of the following tools,
their uses being fully described in the ensuing
instructions.
The first two tools can be made up to the dimen­
sions given.
I. Dummy layshaft spindle f (19 mm.) diameter
x 6½" (165·1 mm.) long-made up.
2. Dummy selector shaft¼" (11 ·1 mm.) diameter
x 5" (127 mm.).-3 required.
3. Selector shaft loading tester clamp. (Churchill
No. R.G.62 or any suitable clamp to attach to
the end of the selector shaft).
4.
Circlip pliers V.L.C. 7065 ("C" and
"A"
points).
5. Socket spanner RG.317 for malnshaft front nut.
SELECTOR SHAFTS AND FORKS
To remove and refit (Figs. 2 and
3)
It
Is Imperative that these are removed REARWARDS
only.
Use dummy selector shaft as described under
"TOOLS".
4th re-issue
Page 5
Carefully tap out reverse selector shaft (64). Note
the distance piece (66) at the rear of the selector
fork.
Carefully tap out the I st and 2nd and 3rd and 4th
selector shaft (55 and 59).
Remove the selector forks.
Adjustment of axial load between 3rd and 4th
selector shaft and fork
This operation should be carried out before
assembling the 3rd and 4th speed selector shaft and
fork into the gearbox; proceed as follows:-
Grip the 3rd and 4th speed selector fork In a vice;
Insert shim/s, spring and ball, then the selector
shaft, depressing the ball by Inserting a punch.
The axial load necessary to move the selector
shaft groove across the ball
in
the fork should
be 25 lbs (11 ·3 kg.) to 30 lbs. (13·6 kg.). This may
be tested by means of a suitable spring balance,
attached to the end of the selector shaft by a hand
vice or the Churchill selector shaft loading tester
VLC No. RG.62. Adjust axial load to the above
figure by addition or removal of shims. As it will
be necessary to detach the selector shaft from the
fork In order to assemble to the gearbox it will be
necessary to retain the adjusted ball and spring in
the fork by means of a dummy selector shaft as
previously described.
With the abov� exception, refitting is a reversal of
the preceding Instructions.
Fis, 2. Checking of axial load of 3rd and 4th selector
shaft and fork.