Reliant Kitten Estate, Руководство по ремонту

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Page 56
12. Lift out the laygear assembly and the two thrust washers.
13.
Withdraw the reverse gear shaft through the rear of the
gearbox and lift out the reverse gear.
14. Secure the rear cover including the mainshaft assembly in a
vice, release the tab washer, unscrew the mainshaft nut and remove
the tab washer and coupling flange from the mainshaft.
15 . Remove the rear cover from the mainshaft assembly.
Mainshaft Dismantling and re-assembly
To dismantle
1. Remove the first speed gear, bush and bush key complete
with baulk ring from the mainshaft.
2. Remove the first/second gear selector sleeve.
Note: It is advisable to carry out this operation with the sleeve
wrapped in a suitable piece of cloth which will avoid losing any of the
sets of balls, blocks, springs and plungers from the synchro body.
3.
After removing the sleeve, recover the springs, balls, blocks
and plungers from the cloth.
4. Repeat this operation for the third/fourth selector sleeve.
5. Remove the circlip from the spigot end of the mainshaft.
6. Using tool No. RT 8778, remove the third/fourth synchro
body from the mainshaft.
7. Withdraw the first speed gear bush key. Using tool RT 8778,
remove the first/second synchro body from the mainshaft and remove
the second speed baulk ring.
8. Remove the second/third speed gear from the mainshaft.
9.
Examine all components for wear and renew if necessary
prior to reassembly.
To reassemble
1. Apply "Moly Grease 799" to second/third gear running
faces on the mainshaft.
2.
Fit the third speed gear and baulk ring on the mainshaft.
3. Secure the woodruff key in its seating on the mainshaft.
4. Locate the third/fourth synchro body on the mainshaft
pressing in to position and fit the circlip.
5. Fit second speed gear and baulk ring to mainshaft followed
by the thrust washer. Ensure that the thrust face of the washer abuts
the gear.
6. Secure the second woodruff key in its location on the
mainshaft.
7. Locate the first/second synchro body on the mainshaft and
press in to position.
8. To facilitate further assembly, position the mainshaft in an
assembly "pot" or a vice.
9. Fit the three springs and plungers to the third/fourth
synchro body.
10. Slide the third/fourth synchro sleeve over the synchro body
leaving sufficient room to enable fitment of thrust blocks and balls in
the following operation.
11. Fit three thrust blocks leaving the synchro body ball
seatings completely visible.
12. Seat the synchro body ball in the thrust block, press the ball
down on to the plunger and slide the thrust block between the sleeve
and the synchro body.
13. Repeat instruction 12 for the two remaining balls.
14. Slide the third/fourth synchro sleeve along the synchro
body until it "clicks" in to position.
Note: Ensure that the sleeve is not pushed in too far, otherwise the
synchro balls and thrust blocks will be disturbed.
15.
reposition the mainshaft in a vice or assembly "pot" to
facilitate first/second synchro body assembly.
16. Fit springs and plungers to the synchro body.
17.
Slide first/second synchro sleeve over synchro body leaving
sufficient room to enable fitment of thrust blocks and balls. Ensure
the teeth of the synchro sleeve are facing forward.
18. Fit the three thrust blocks, leaving synchro ball seatings
completely visible.
19. Seat synchro body ball in thrust block, press ball down on to
plunger and slide the thrust block between the sleeve and synchro
body.
20. Repeat instruction 19 for two remaining balls.
21. Position baulk ring on first speed gear.
22. Fit first speed gear bush key into its location in the synchro
body.
23. Apply "Moly grease 799" to gear bush outside diameter and
inner flange face and then fit first gear.
24. Position first gear, including bush and baulk ring, on to
mainshaft splined end.
25. Rotate first gear bush, until it fully locates in the bush key
seated in the first/second synchro body.
Note: Handle mainshaft cluster with care to prevent synchro sleeves
etc from being disturbed.
26. Using tool No. RT 7490 press the rear cover on to the
mainshaft.
Operation 4
Primary gear assembly - dismantling and
re-assembly
To dismantle
1. Prise the primary gear front seal from the gear shaft.
2. Using circlip pliers (Tool No 7066) remove circlip securing
the front bearing to the primary gear.
3.
Remove the spacer and front bearing.
4. Withdraw the needle roller bearing from inside the gear
body.
5. Inspect parts for wear, renewing if necessary.
To re-assemble
Replace components in reverse order. care should be taken when
fitting the front seal that it is not damaged when passing the seal over
the shaft splines. The seal is correctly fitted when it abuts the
shoulder on which is the circlip. It must not abut the circlip.
Note: The lip on the front seal must face forward.
Operation 5
Rear cover - dismantling and re-assembling
To dismantle
1. Remove circlip securing the rear bearing to the cover.
2. Using tool RT 7490, press out the rear bearing and
speedometer gear.
3. Prise out the rear cover oil seal.
To re-assemble
1. Press new seal into cover using tool RT 7489 and drive
handle 550 ( Figure 3 ).
2. Check rear bearing and speedometer gear for wear, renew
if worn.
3. Replace he bearing, circlip, speedometer gear, and fit the
coupling flange oil seal.
Operation 6 Lay gear - dismantling and re-assembly
1. Examine the lay gear assembly, gear teeth and renew
complete assembly if obvious wear or damage is apparent.
2.
The lay gear needle rollers should also be checked. remove
worn items with a suitable drift.