B2CG4TK1 - 406D9 BE3 GEARBOX

DISMANTLING - ASSEMBLY INPUT SHAFT

1 - PRELIMINARY OPERATIONS

Stripping the gearbox .

Removing the bearing guide tube .

Removal : Gearbox casing .

Removal : Input and output shafts .

2 - DISMANTLING

remove the rear bearing (1) using a press and tool [2] pressing under 3rd gear (2) and protecting the end of the shaft with its nut (3) .

WARNING : the flat surface (A) of tool [2] must be directed to the gear side so as not to press on the teeth .

Remove in succession :

• the 4th speed driving gear (4) and its thrust ring (5)
• the sliding gear and its hub (6) (mark the 4th speed gear and the position of the hub in relation to the synchroniser)
• the 3rd speed driving gear (2)

Remove the front bearing (7) using a press and tool [2] .

Remove the input shaft rear bearing outer race using the drift [3] .

3 - ASSEMBLY

Always renew :

• the bearings
• the nut

Use parts which are clean and free from faults .

Check that the shaft bearings are in perfect condition, no knock or scratch marks .

Match up the marks made during removal .

Lubricate the components as they are refitted .

refit the front bearing (7) using a press, the fitting drift [4] and tool [2] .

WARNING : the flat surface (A) of tool [2] must be towards the gear end so as not to press on the teeth .

Fit :

• the 3rd speed driving gear (2)
• the synchroniser sliding gear with its hub (6), following the markings made on removal (in the event of re-use of parts)
• the 4th speed gear thrust collar (5)
• the 4th speed driving gear (4)

refit the rear bearing (1) using a press, the fitting drift [4] and tool [2] .

WARNING : the flat surface (A) of tool [2] must be towards the gear end so as not to press on the teeth .

IMPERATIVE : place the housing on a metal plate (10 mm) to prevent it from being damaged on fitting .

refit the outer race of the new bearing in the housing, using a press, and using the fitting drifts [3] and [5] .

Observe the cleaning and refitting conditions .

Removing the bearing guide tube .

Refitting the bearing guide tube .

Checking-adjustment of the input shaft bearings .

Refitting the input and output shafts .

Refitting the gearbox cover .

Reassembling the gearbox .