Gearbox Dimensioning
Checked dimensions:
- Distance «A» between the mating surface of the gearbox housing and the drive shaft, the end of the 5th gear clutch (the nominal value is 141.8 mm.
- Distance «IN» - between the end surface of the 4/5th gear synchronizer and the mating surface of the intermediate crankcase (nominal value is 140.4mm).
- Distance «WITH» - between the mating surface of the intermediate crankcase and the inner race of the bearing.
- Distance «A» adjustable with shims (43a) drive shaft.
1. Press in the drive shaft (2) together with ball bearing (43) into the gearbox housing and install the front cock with gaskets.
2. Using a vernier caliper, measure the distance from the mating surface of the gearbox housing to the end face of the clutch. The nominal value is 141.8 mm. Determination of gasket thickness:
Rated value (141.8 mm) - Measured distance (141.4 mm) = Gasket thickness (0.4 mm).
Gaskets are available in thicknesses of 0.2, 0.3 and 0.9 mm.
3. Carefully install the drive shaft with ball bearing into the gearbox housing. 4. Press in gaskets (arrow) onto the ball bearing and press the drive shaft into the gearbox housing using a punch. Check nominal distance.
5. Distance «IN» gaskets (36) in the front friction ring (35) helical gear 2nd gear (33).
6. Press in the ball bearing (70) into the intermediate housing and tighten the bolts (69) retaining ring (73) up to 30 Nm.
7. Using a press, seat the intermediate housing on the driven shaft.
8. Using a vernier caliper, measure the distance from the 4th/5th gear synchronizer to the mating surface of the intermediate case. The nominal value is 140.4 mm. Determination of gasket thickness:
Rated value (140.4 mm) - Measured distance (140.1 mm) = Gasket thickness (0.3 mm).
Gaskets are available in thicknesses of 0.2, 0.3, 0.5 and 1.4 mm.
9. Remove the intermediate plate from the driven shaft and adjust the gap with shims. 10. Distance «WITH» adjustable with shims (66) on a ball bearing in the intermediate plate.
11. Fix the driven shaft with the intermediate plate in a vise and, using a vernier caliper, measure the distance from the rear surface of the intermediate housing to the inner race of the bearing. Determination of gasket thickness:
Measured distance (25.9 mm) - Nominal value (24.3mm) = Gasket thickness (1.6 mm).
Gaskets 0.1, 0.3, 0.5 and 1.4 mm thick.
12. Adjust the distance with shims by placing them between the ball bearing and the friction ring.
13. Remove the intermediate housing and press out the driven shaft ball bearing.