Gearbox

D

SECTION D9
REFITTING GEAR CLUSTER AND SELECTORS
After inspection of components as in Section D6 commence reassembly as follows:
1	Heat the gearbox shell and press the mainshaft sleeve gear bearing into the gearbox until it is fully home.
2	Fit the mainshaft sleeve gear seal bearing evenly into the housing, lipped side towards the bearing. Take care not to allow the seal to enter obliquely into the housing.
3	Fit the layshaft ball journal bearing fully home into the casing.
4	Fit the quadrant with 'O' sealing ring into the gearbox shell bush and secure with the washer and bolt
5	Lift the knuckle end of the quadrant until the top inside radius is directly in line with the top front cover stud (see Fig. D2) fit the camplate and sealing ring, engaging the teeth of the quadrant and camplate so that the notched edge of the camplate is towards the gearbox sprocket and the smooth edge towards the gearbox inner cover, the last notch at the bottom engaging with the camplate index plunger (see Fig. D2).

6	Secure the camplate with nut and washer.
7	Fit the sleeve gear with bushes through bearing and seal and fit sprocket spacer.
8	Fit the countershaft sprocket as in Section D8.
9	Fit the mainshaft through the sleeve gear.
10	Fit the 3rd gear free pinion and bush to the layshaft.
11	Fit the layshaft fixed pinion to the layshaft, flat side first (see layout in Fig. D4). This will leave the shouider on the pinion to allow for clearance for the bearing.
12	Offer the layshaft to the bearing in the gearbox shell. This should be a hand push fit.
13	Assemble the mainshaft 3rd gear with selector fork to the mainshaft and engage the peg with the inboard cam track (see Fig. D4).
14	Assemble the mainshaft 2nd gear with bush to the mainshaft, dogs inboard.
15	Assemble the layshaft second gear with selector fork and selector fork spindle, engaging the pin with the outboard cam track.
16	Slide the selector fork spindle through the second selector fork and screw home into the gearbox shell.
17	Fit the layshaft 1st gear.
18	Fit the mainshaft 1 st gear with long extension outboard.
19	Prior to fitting the gearbox inner cover as in Section D10, place the quadrant roller in position. This is important since the roller cannot be fitted at a later stage.

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