Sunbeam ALPINE I SERIES: APLINE II SERIES, Workshop Manual

Page: 141 / 413

WSM. 114
Section E (Gearbox & Overdrive)
FRONT COVER ASSEMBLY
To remove and refit (Fig. 3)
The front cover assembly can only be withdrawn
after the layshaft cluster (38) has been lowered into
the bottom of the gearbox c:asing (1).
Remove top and rear covers and selectors as
previously described.
Remove the four securing setscrews from the front
cover (5).
Remove setscrew and washer securing lock plate
(47�.
Remove lock plate by sliding it downwards.
Displace layshaft (39) by entering dummy layshaft
from the front, pushing it rearwards until clear of
the fixed thrust washer (43) so lowering the layshaft
cluster assembly to the bottom of the casing.
It is essential that the layshaft spindle is entered and
removed through the rear of the casing. The hole
in the front of the casing Is of smaller diameter than
that in the rear, and incorrect removal and refitting
will destroy the oil-sealing thereby obtained.
Th,e front cover assembly should now be withdrawn
from the casing.
Do not lose the needle rollers (14) from the main­
shaft spigot bearing.
Remove the fourth speed baulking ring (33) from
the synchrohub (30).
In order to maintain efficient functioning of the
synchronising mechanism it is advisable to correlate
each baulk ring to Its mating cone by some form of
identification,
e.g.,
using a sharp Instrument, scribe
in a prominent position the numbers 2, 3 and 4
indicating second, third and fourth speeds.
When refitting the front cover assembly It Is
essential that the drain hole is placed In the six
o'clock position, and a new paper joint fitted
between the gearbox casing and the front cover.
4th
re-issue
Page7
To dismantle and reassemble ( Figs. 3 and 4)
Remove circlip (18) securing bearing (15) in front
cover (5).
Press stemwheel assembly, complete with bearing,
out of front cover.
Remove circlip (19) securing bearing (15) and
abutment washer (17) to stemwheel (13).
Press bearing off stemwheel.
Remove bearing shield (16). (Do not omit this on
reassembly).
Remove oil seal. (This is a press fit in the cover).
Reassembly of the front cover assembly Is a reversal
of the preceding instructions with particular
attention to the following points:-
The clrclip (19) securing the bearing to the stem­
wheel must always be renewed.
In this assembly a predetermined amount of float Is
provided for and is controlled by the class of fit of
the members of the ball bearing.
Fi1. 4.
Pressing
stem
wheel
out
of
cover