R380 GEARBOX. Manual — part 10
MANUAL GEARBOX
OVERHAUL
19
Remote gear change - Type D gearbox
NOTE: The remote gear change fitted to
Type D gearboxes is not repairable item. It
must be renewed if it is found to be
excessively worn.
Inspection
1. Check selector rod bushes in remote housing
for wear.
NOTE: Bushes may be pressed in and out
of remote housing using a hand press and
suitable mandrel.
2. Check selector rod for wear, replace if
necessary.
3. Check anti - rattle spring for distortion and
plunger for wear; replace if necessary.
4. Check gear lever ball pin, cross pins and bush
selector rod yoke balls for wear, and replace if
necessary. If yoke balls are worn, remove and
discard circlip, press ball and seating out of
yoke.
5. Lubricate replacement ball and seating with
multi - purpose grease and press into yoke;
secure using new circlip.
6. Check bias spring for distortion, replace if
necessary.
7. Check condition of mounting rubbers, replace
as a set if necessary.
Reassemble
1. Lubricate selector rod and bushes with multi -
purpose grease, insert rod in remote housing.
2. Lubricate gear lever ball pin and selector rod
yoke balls with multi - purpose grease.
3. Fit yoke to selector rod, fit and tighten pinch
bolt.
4. Assemble anti - rattle spring and plunger to
gear lever.
5. Fit gear lever ensuring ball pin is located in
yoke and anti - rattle spring and plunger are
not displaced.
6. Fit gear lever cap, fit and tighten bolt.
NOTE: Do not fit bottom cover plate at this
stage.
7. Slacken bias spring adjustment bolt locknuts.
8. Fit bias spring, bridge plate liners and bridge
plates.
9. Fit and tighten bolts and countersunk screws.
NOTE: Final adjustment of bias spring is
carried out after remote gear change is
fitted to gearbox.
MANUAL GEARBOX
20
OVERHAUL
Transfer box selector housing - Type A gearbox -
Overhaul
Dismantle
1. Slide gaiter off gear lever.
2. Remove 4 bolts securing gaiter support plate
and gate plate.
3. Remove gaiter support plate and gate plate,
discard gaskets.
4. Remove and discard spring clip retaining
selector fork clevis pin.
5. Remove clevis pin from selector fork, remove
and discard 2 bushes.
6. Remove and discard circlip retaining nylon ball
seating.
7. Remove gear lever, recover nylon seating and
ball
8. Remove 2 countersunk head screws securing
end cover to housing.
9. Remove end cover, remove and discard 2 ’O’
rings.
10. Withdraw cross shaft.
11. Remove selector fork, remove and discard 2
’O’ rings.
12. Clean all components.
MANUAL GEARBOX
OVERHAUL
21
Inspection
1. Check gaiter for splits and damage.
2. Check nylon seating and ball for wear, replace
if necessary.
CAUTION: Seating and ball should be
renewed as an assembly.
3. Check selector fork and clevis pin for wear.
4. Check cross shaft and end cover for wear.
5. Replace components as necessary.
Reassemble
1. Smear new ’O’ rings with gearbox oil and fit to
selector fork, position fork in housing.
2. Smear cross shaft with multi - purpose grease
and locate longest end of shaft in selector fork.
3. Smear new ’O’ rings with gearbox oil and fit to
end cover.
4. Position end cover on cross shaft, fit and
tighten countersunk screws.
5. Assemble ball and nylon seating to gear lever
ensuring that groove in seating is towards
cross shaft.
6. Smear ball and nylon seating with multi -
purpose grease and locate in cross shaft;
retain with a new circlip.
7. Position new bushes to gear lever, locate in
selector fork and fit clevis pin.
8. Fit new spring clip to retain clevis pin.
9. Position gate plate and gaiter support plate to
housing, use new gaskets.
10. Fit retaining bolts and tighten to 15 Nm.
11. Fit gaiter.
Synchromesh assemblies - Overhaul
1. Remove spring clips from both sides of
assembly.
2. Remove slippers and separate the hub from
the sleeve.
3. Examine all parts for damage and wear
including spring clips for tension.
4. Check no excessive radial movement exist
between inner members and mainshaft splines.
5. Examine inner and outer splines for wear.
MANUAL GEARBOX
22
OVERHAUL
6. Examine the dog teeth on all gears for wear
and damage.
NOTE: Example ’A’ shows a tooth in good
condition. Example ’B’ shows the rounded
corners of a worn tooth.
7. Replace unit if excessively worn.
Reassembly
8. Refit inner hub to sleeve.
NOTE: Hubs and sleeves have a master
spline combination and can only be
assembled one way. The sleeves are
further identified with a series of half moon
notches which clearly identify which side of the
assembly faces which gear. Ensure the slot in
the hub aligns with the centre notch on the
sleeve.
Assy
Hub
Sleeve
Against
Gear
1st/2nd
-
1 Notch
1st
2 gear
side
-
2nd
3rd/4th
-
3 Notches
3rd
-
-
4th
5th/Rev
-
5 Notches
5th
9. Fit slippers and secure with a spring each side
of the synchromesh assembly ensuring the
step on each spring locates on a different
slipper.
NOTE: 5th and reverse synchromesh hubs
have different springs noted by their
yellow colour.
Checking baulk ring clearances
Check clearance of all baulk rings and gears by
pressing the baulk rings against the gear and
measuring the gap. The minimum clearance
should be 0.5mm (0.020in).
Input shaft - Overhaul
1. Examine the gear and dog teeth for wear and
damage.
2. Using tool LRT-99-004 and LRT-37-004
remove pilot bearing track.
NOTE: Ensure that the bearing is
supported by the lip inside LRT-37-001.
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст