Reliant Kitten Estate, Руководство по ремонту

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Page 52
Section G
Contents
Description
Routine maintenance
Operation 1
Gearbox removal and installation
Operation 2
Dismantling the gearbox
Operation 3
Mainshaft - dismantling and re-assembly
Operation 4
Primary gear assembly - dismantling and
re-assembly
Operation 5
Rear cover assembly - dismantling and
re-assembly
Operation 6
Lay gear and layshaft - dismantling and
re-assembly
Operation 7
Reverse idler gear
Operation 9
To re-assemble the gearbox
Description
The gearbox has four forward gears and reverse with synchromesh on
all forward gears. The gear lever is directly located in the selector
levers through the gearbox top cover.
Routine maintenance
The gearbox oil level should be checked every 6,000 miles (10,000 km)
and topped up if necessary, to keep the oil capacity at a constant 0.64
litres (1.125 pints). It is important that the level be kept correct as any
drop in the level will lead to poor lubrication with possible
transmission damage. To ensure that the internal components are
kept clean, the oil should be changed at 12,000 mile (20,000 km)
intervals.
Operation 1 Gearbox removal and installation
To remove
1. Disconnect the battery.
2. Drain the radiator and disconnect the top hose.
3. Disconnect the distributor HT and LT leads.
4. Remove the fresh air hose.
5. Disconnect the exhaust downpipe at the manifold.
6. From inside the vehicle, prise out the gear lever gaiter and
remove the gear lever knob. Remove the gaiter from the lever.
remove the centre console. Prise out the retaining "C" clip from the
gear lever top ball joint in the gearbox top cover, accessible through
the gaiter aperture. Lift out the gear lever and plug the hole with a
clean non-fluffy rag to avoid ingress of dirt.
7. Place the vehicle on a ramp or stands. remove the anti-roll
bar clamping rubber from the left hand chassis rail.
Gearbox
8. Repeat for the right-hand clamp and lower the anti-roll bar
down, away from the chassis.
9. Disconnect the speedometer cable.
10. Disconnect the clutch cable from the trunnion, remove the
lock nut and withdraw the cable from the trunnion. Pull the cable
outer sleeve from the retaining hole in the engine back plate.
11. Remove the four nuts, lock washers and bolts securing the
drive shaft to the rear axle flange, lower the drive shaft to facilitate
access to the gearbox flange and remove the front nuts, lock washers
and bolts followed by the drive shaft.
12. Support the engine and gearbox assembly from under the
sump.
13. Remove the four bolts securing the gearbox rear mount to
the chassis cross member.
14 . By means of a jack, carefully lower the engine and gearbox
assembly, which will tilt on the front engine mountings, until the
gearbox rear support is clear of the chassis cross member.
15. Remove the bell housing nuts, lock washers and bolts and
withdraw the gearbox assembly from the engine.
To install
1. Raise the gearbox carefully and align the spigot on the
primary shaft with the spigot bearing in the flywheel and slide the
gearbox forward engaging the splines on the primary shaft with the
clutch plate. Locate the fixing studs into the rear engine plate and
secure the engine and gearbox together with six nuts, two bolts and
lock washers tightening to a torque of 1.66 to 2.07 kg/m (12 to 15
lb/ft).
2. Using a jack under the sump, raise the engine and gearbox
assembly, line up the gearbox support with the chassis mounting and
secure with the four nuts, bolts and lock washers.
DO NOT forget to
attach the chassis earth braid. Tighten to a torque of 2.07 to 2.49
kg/m (15 to 18 lb/ft).
3. Reconnect the drive shaft to the gearbox using four bolts,
nuts and lock washers and tighten to a torque of 3.46 to 4.15 kg/m (25
to 30 lb/ft). Raise the rear end of the drive shaft and reconnect to the
axle flange. Tighten as for front fixings.
4. Reconnect the speedometer cable to the gearbox.
5. Refit the clutch cable into the retaining hole and reconnect
to the trunnion and adjust.
6. Secure the exhaust downpipe to the manifold with a new
gasket and two brass nuts.
7. Refit the exhaust support bracket to the bell housing stud
and secure with a nut and lock washer.
8. Refit the anti-roll bar to the chassis securing with two bolts
and washers on each side member.
9.
Inside the vehicle, re-insert the gear lever into the ball
mount and secure with the "C" clip. Refit the centre console.
10. Push the gear lever gaiter over the gear lever and locate in
the centre console aperture.
11. Refit the gear knob.
12. reconnect the HT and LT cables.
13. Reconnect the fresh air hose.
14. replace the radiator top hose and refill the cooling system.
15.
Reconnect the battery.