Chapter 3: Disassembly and Reassembly
4000 Mk2 Wheel Drive Service Manual 83158-1
9
4000 Mk2 Wheel Drive
12.
Remove the 21 ball bearings (12), taking care to retain them for reassembly (e.g. in the
inside of upturned front cover).
13.
Lift off the machined pulley (13).
Motor and gearbox
14.
Unscrew the plastic collar nut (14) by turning it anti-clockwise, then remove the rubber
cap (15).
15.
Unscrew the motor tube (16) by hand (turning it anti-clockwise) and then remove it.
16.
Lift off the motor assembly, consisting of: motor sleeve (17), motor (18), motor clamp
(19), O-ring (20), motor loom (21) and gasket (22).
17.
Remove the gearbox (23) by pushing it out from the rear of the back cover (24).
3.3.
Reassembly
CAUTION:
Do NOT use mineral-based solvents (e.g. WD40) to lubricate or clean the wheel drive as
they will damage the material. The wheel drive is designed to run without lubrication.
Gearbox
1.
Fit the gearbox (23) by inserting it from the inside of the back cover (24). Ensure that the
locating slots on the gearbox are aligned with the lugs in the back cover.
2.
Place the machined pulley (13) onto the gearbox shaft, with the recessed face on top.
Clutch eccentrics
3.
Fit the 2 clutch eccentrics (8) with their flanges downwards, so that they are clear of the
foul pins on the back cover. Note: the 2 clutch eccentrics are identical.
4.
Fit the 2 clutch rollers (5) over the clutch eccentrics. Note: the 2 clutch rollers are
identical.
Drive ring and bearing cage
5.
Place the drive ring (11) onto the back cover, with its lipped edge uppermost.
6.
Place the 21 ball bearings (12) back into the ball groove.
7.
Roughly distribute the ball bearings around the ball groove – this should secure the drive
ring.
8.
Fit the 3 parts of the bearing cage (10):
•
clip the first part of the bearing cage into the ball groove, capturing 7 ball bearings in
the cage
•
repeat for the other 2 parts of the bearing cage
•
when you have fitted the 3 parts of the bearing cage, check that the drive ring is free
to rotate
