Reliant Kitten Estate, Руководство по ремонту

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Page 57
Figure 3 Replacing rear cover oil seal
Care should be taken when fitting new needle roller bearings not to
damage the bearing cage (see note on needle roller bearings in
Section F, Operation 2 )
3. If signs of scoring are apparent on the layshaft, due to worn
needle roller bearings, it will have to be renewed.
Operation 7 Reverse idler gear assembly and shaft
1. Check reverse idler gear teeth and renew assembly if
necessary.
2. Inspect bushes and if worn, drive out old bushes with a
suitable drift and fit new ones.
Ensure the end face of the bushes finish flush with the gear face,
3. Check gear shaft for scoring and replace if necessary.
Operation 8 To re-assemble the gearbox
1. Refit reverse idler gear and shaft in to the gearbox case
with the select groove to the rear.
2.
Position the laygear assembly with its thrust washers in to
the base of the gearbox.
3. Refit the primary gear assembly in to the bell housing
location.
Note: Drive carefully in to position until the bearing retaining ring is
flush with the case.
4. feed in the mainshaft assembly, taking great care not to
dislodge the synchro thrust blocks and balls.
5. Refit the rear cover with a new gasket to within 6.35 mm
(¼ in) of the gearbox face (to allow rotary movement and facilitate
positioning of the layshaft).
6.
Turn the gearbox on to its top face and slide the layshaft
through the thrust washers and laygear assembly until it mates in its
bore with the rear of the box.
Note: The tang end of the layshaft must be at the front.
7. Position the tang end of the reverse shaft to engage with
the horizontal slot in the rear cover, then bolt the rear cover fully
home.
8. Refit the coupling flange on the mainshaft spline, fit the
washer and tab washer and secure with the mainshaft nut. Tighten to
a torque of 6.92 kg/m (50 lb/ft). Bend over the tab washer to secure
the nut.
9. Return the gearbox to an upright position and insert the
reverse, 1st/2nd and 3rd/4th selector forks on to the shafts.
10. Replace the two interlock balls in to the cross drilling in the
bell housing, locating in position with grease.
11. Line up the reverse selector shaft in the selector fork and
drive home the mills retaining pins.
12. Ensuring the interlock pin is in position, replace the1st/2nd
selector shaft in the selector fork and lever. Secure in position with
the mills pin.
Note:
Rotate the shaft and fit the horizontal pin first, in the selector
lever, before pinning to the selector fork.
13. Replace 3rd/4th selector shaft into the mating fork and
lever, again retaining in position with mills pins.
14. Refit front cover.
Note: Ensure that the oil seal is correctly positioned on the primary
gear shaft (see Operation 4 ).Secure front cover to gearbox with seven
nuts and lock washers. Do not attempt to move selectors or change
any gear until the front cover is secured as this will result in forcing
the mainshaft assembly apart.
15. Replace the selector shaft detent balls and springs and refit
top cover and gasket, retaining in position with eight set screws and
locking washers.
16. refit the clutch fork and lever assembly.