B2CG4SK1 - 406D9 BE3 GEARBOX

REMOVAL INPUT AND OUTPUT SHAFTS

1 - PRELIMINARY OPERATIONS

Stripping the gearbox .

Removing the bearing guide tube .

Removal of the gearbox casing .

2 - REMOVAL

2 - 1 - UNBRAKED REVERSE WHEEL

Engage reverse gear .

Remove the reverse shaft and sliding gear (1) .

2 - 2 - REVERSE GEAR WITH BRAKE

Engage reverse gear .

WARNING : support the reverse gear + brake assembly ; risk of ejection of the balls and spring .

Remove the reverse shaft and sliding gear (2) .

Rotate and remove the 5th gear shaft (3) .

Turn the fork shaft (4) .

Remove the 1st/4th shaft (4) by pulling upwards .

Pivot the fork (5) .

Free the clutch housing shafts by a few millimetres .

Tilt the right hand part of the fork downwards .

Remove the fork (5) .

Pull the gear lever (6) as far as possible .

Tilt the lever (6) .

Lift the interlock key (7) to retain the assembly in this position .

Remove the 1st/2nd gears and forks assembly .

3 - REFITTING

Pull out the gear lever (6) fully and immobilize it in this position on the axle housing in that position by turning it downwards .

Raise the interlocking key (8) .

Couple the input shaft and the output shaft with the 1st/2nd gear fork .

Position the gears in the casing .

Engage reverse gear .

Fit :

• the 3rd/4th fork (9)
• the 1st/2nd - 3rd/4th gear fork shaft (4)

Engage neutral .

Refit the 5th gear fork shaft (3) .

Engage reverse gear .

3 - 1 - UNBRAKED REVERSE WHEEL

Refit the reverse gear and shaft (1), the tooth lead facing downwards (A) .

NOTE : check the protrusion of the shaft positioning pin (10) : 5 mm .

3 - 2 - REVERSE GEAR WITH BRAKE

Assemble the reverse gear brake .

WARNING : support the reverse gear + brake assembly ; risk of ejection of the balls and spring .

Refit the reverse gear and shaft (1), the tooth lead facing downwards (A) .

NOTE : check the protrusion of the shaft positioning pin (10) : 5 mm .

Observe the cleaning and refitting conditions .

Reassembling the gearbox .