Install drive shaft, main shaft and countershaft

Housing

Produtos para reparos

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1 Install the countershaft (6).

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2 Assemble the set of secondary shaft (7) with the fork of the 5th and reverse idler gear, which must be properly set in the channels of the synchronizer cover.

To ease the assembling process and the gear shifting, move slightly the countershaft. Grease the speedometer gear, to avoid its fall.

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3 Apply grease on the activating pin of the neutral switch (A) and install it in the 5th and idle reverse gear shift lever with the engage section already assembled.

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4 Attach the 5th and idle reverse gear shift lever (5) to the engage section already assembled; make sure they are properly attached to the locking ball.

 Make sure that the coupling balls that inhibit double engaging do not come out from their seats.

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5 Place the 3rd and 4th gears fork in the channels of the corresponding synchronizer cover and insert the shift lever (5) in the fork.

6 Apply some grease in the mechanism that inhibits double engaging (A) and install it in the shift lever (5).

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7 Insert the engage section of 3rd and 4th gears in the shift lever (5) and push the shift lever (5) in its seat in the case; make sure that you attach the shift lever (5) to the locking ball of the mechanism that inhibits double engaging.

 Make sure that the coupling balls that inhibit double engaging do not come out from their seats.

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8 Place the 1st and 2nd gears fork in the channel of the corresponding synchronizer cover and insert the shift lever (5) in its hole.

9 Push the shift lever (5) of 1st and 2nd gears into its seats in the case; make sure that you attach the it to the locking ball of the mechanism that inhibits double engaging.

 Make sure that the coupling balls that inhibit double engaging do not come out from their seats.

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10 Align the holes of the 3rd and 4th gears fork with the ones of the shift lever, and install a new roll pin (4).

 Use a new pin puller with diameter of 4 mm.

 Use a wooden block between the lever and the gears, to avoid damages to the lever or to its seat.

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11 Align the holes of the 3rd and 4th gear sections with the ones of the shift lever, and install a new roll pin (4).

 Use a new pin puller with diameter of 4 mm.

 Use a wooden block between the lever and the gears, to avoid damages to the lever or to its seat.

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12 Align the holes of the 5th and reverse idle gears fork with the ones of the shift lever, and install a new roll pin.

 Use a new pin puller with diameter of 5 mm.

 Use a wooden block between the lever and the gears, to avoid damages to the lever or to its seat.

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13 Align the holes of the 1st and 2nd gears fork with the ones of the shift lever (5), and install a new roll pin.

 Use a pin puller with diameter of 5 mm.

 Use a wooden block between the lever and the gears, to avoid damages to the lever or to its seat.

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14 In the end of the assembly of the shift levers (5), forks and engaging sections, the upper parts of the shift levers (5) should be aligned and the engaging sectors should be aligned in NEUTRAL position.

15 Test the double engaging mechanism by trying to engage two gears at the same time: engage any gear and try to engage another gear.

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16 Install the synchronizer ring of 4th gear (B) in the secondary shaft.

 The synchronizer ring of 4th gear does not have EFM lining.

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17 Install the primary shaft (8), fitting it in the secondary shaft bearing cone.

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18 Grease and install the needle roller bearings in the reverse idle gear (1).

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19 Place the reverse idle gear (1) in the case, with the needle roller bearing. The bounce must be upwards.

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20 Insert the reverse idle gear axle (2).

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21 Install the fastening screws in the idle gear axle (3).

 Apply Loctite 262 in the screw thread.