B2BJ02K1 - 406D9 ML5T GEARBOX

DISMANTLING - ASSEMBLY CLUTCH HOUSING (SECOND ASSEMBLY)

1 - CLUTCH RELEASE BEARING GUIDE REMOVAL-REFITTING

Remove :

• the bolts (1)
• the clutch release bearing guide (2)

Fit the stop guide (2) .

Tighten the bolts (1) to 2 daN.m .

2 - IDENTIFICATION OF THE DIFFERENT CLUTCH FORK AND SHAFT ASSEMBLIES

2 - 1 - EARLIER ASSEMBLY

Clutch fork (3) .

Fork shaft (4) .

Fork bottom bearing (5) .

Dust shield (6) .

Fork shaft top bearing (7) .

2 - 2 - LATER ASSEMBLY

Clutch fork (8) .

Fork shaft (9) .

Fork bottom bearing (10) .

Fork shaft top bearing (11) .

3 - IDENTIFICATION OF THE DIFFERENT PARTS

3 - 1 - CLUTCH FORK

Earlier assembly (12) .

Later assembly (13) .

3 - 2 - FORK SHAFT

Earlier assembly (14) .

Later assembly (15) .

3 - 3 - FORK SHAFT BEARINGS

Earlier assembly (16) .

Later assembly (17) .

4 - CLUTCH FORK SHAFT AND BEARING REMOVAL

4 - 1 - REMOVAL - (EARLIER ASSEMBLY)

Drift out the pin (18) retaining the fork to the shaft .

Remove :

• the clutch fork shaft (19)
• the rubber seals (20)
• the fork (21)
• the fork shaft bearings (22)

4 - 2 - REFITTING - (EARLIER ASSEMBLY)

NOTE : Parts Div. does not supply this shaft and fork assembly; it must be replaced by the new assembly .

4 - 3 - REMOVAL - (LATER ASSEMBLY)

Remove the bearing (23) by pressing on the 2 tongues (24-25) .

Remove :

• the clutch fork shaft (26)
• the fork (27)
• the bottom bearing (28)

4 - 4 - REFITTING - (LATER ASSEMBLY)

Fit :

• the bearing (28) without greasing it

NOTE : grease the clutch fork bushes with MOLYKOTE BR2+ grease .

Fit :

• the fork (27)
• the clutch fork shaft (26)
• the bearing (23)