Shaft - Output

Shaft - Output

Service Repair No - 37.20.25

Disassembly

1. Remove gearbox selector fork - set
2. Remove gearbox front cover.





3. Remove and discard oil seal and bearing tracks from front cover.





4. Remove and discard bearing tracks from centre plate, collect selective shims.





5. Using tool LRT-99-002 and support bars under 1st gear, press output shaft bearing from output shaft.





6. Remove 1st gear, bearing collar, needle roller bearing and synchromesh rings.
7. Noting its fitted position, remove 1st/2nd gear synchronizer hub, 2nd gear synchromesh rings, 2nd gear and needle roller bearing.





8. Using tool LRT-99-002 and support bars under 3rd gear and press off output shaft pilot bearing.





9. Remove spacer, 3rd / 4th gear synchronizer hub, synchromesh baulk rings, 3rd gear and needle roller bearing.
10. Remove output shaft.





11. Using tool LRT-37-043 and LRT-99-002, remove taper roller bearing from input shaft.





12. Using tool LRT-37-044 and LRT-99-002, remove bearing from splined end of layshaft.





13. Using tool LRT-37-022 and LRT-99-002, remove bearing from 4th gear end of layshaft.

Reassembly

1. Clean layshaft, input shaft and output shaft bearing surfaces.





2. Using tool LRT-37-022, LRT-37-044 and LRT-99-002, press new bearing onto splined end of layshaft.





3. Using tool LRT-37-022 and LRT-99-002, press new bearing onto 4th gear end of layshaft.





4. Using tools LRT-37-043, LRT-37-043/2 and LRT-99-002, press new bearing onto input shaft.
5. Using tool LRT-99-002 and a suitable mandrel, fit input shaft outer bearing track to front cover.
6. Fit layshaft bearing track to front cover.
7. Using tool LRT-99-002 and a suitable mandrel, fit pilot bearing outer track to input shaft.
8. Clean synchronizer hubs, gears and bearings.
9. Position output shaft in protected vice jaws, output end upwards.
10. Fit 2nd gear bearing, 2nd gear and synchromesh baulk rings onto output shaft.
11. Position 1st / 2nd synchronizer hub onto output shaft. Ensure that baulk rings are correctly located in hub.
12. Position 1st gear synchromesh baulk rings, needle roller bearing, 1st gear and bearing collar onto output shaft. Ensure baulk rings are correctly located in hub.
13. Remove output shaft from vice.





14. Using tool LRT-37-001, LRT-37-044 and LRT-99-002, press taper bearing onto output shaft.





15. Using a feeler gauge, check end float of 1st gear between gear and collar flange:
^ New = 0.05 - 0.20 mm (0.002 - 0.008 in)
^ Service limit = 0.327 mm (0.012 in)





16. Using a feeler gauge, check end float of 2nd gear between gear and output shaft flange:
^ New 0.04 - 0.21 mm (0.0016 - 0.0083 in)
^ Service limit= 0.337 mm (0.013 in)
17. Invert output shaft in vise and fit 3rd gear, bearing, baulk rings, 3rd / 4th synchronizer and spacer.
18. Remove output shaft from vice.





19. Using tool LRT-99-002 and a suitable mandrel, press pilot bearing onto output shaft.





20. Check end float of 3rd gear between gear and flange on output shaft:
^ New = 0.11 - 0.21 mm (0.004 - 0.0083 in)
^ Service limit= 0.337 mm (0.013 in)
21. Check output shaft and layshaft end float as follows.
22. The end float setting for both shafts is:
^ New = 0.00 to 0.05 mm (0.0 to - 0.002 in)
^ Service limit = 0.05 mm (0.002 in)
23. Fit front cover to gearbox case without the oil seal and tighten bolts by diagonal selection to 25 Nm (18 ft. lbs.).
24. Position in vice with front cover facing downwards.
25. Fit input shaft to gearbox case less 4th gear baulk ring.
26. Fit output shaft assembly to input shaft.
27. Fit output shaft bearing track and shim to centre plate.
28. Fit centre plate to gearbox case and secure using 8 slave bolts.
29. Rotate output shaft to settle bearings.
30. Fit a suitably large ball bearing into end of output shaft.
31. Position a suitable DTI and zero probe on ball bearing.
32. Lift output shaft and note DTI reading.
33. If reading is incorrect, dismantle and fit shim to give correct end float.
34. Repeat above procedure.
35. Repeat procedure for layshaft end float.
36. Remove and discard 6 bolts and remove gearbox front cover.
37. Fit gearbox selector fork - set.
38. Fit gearbox front cover.