B2CG4UK1 - 406D9 BE3 GEARBOX BE4 GEARBOX

DISMANTLING - ASSEMBLY OUTPUT SHAFT

1 - PRELIMINARY OPERATIONS

Stripping the gearbox .

Removal : Gearbox casing .

Removal : Input and output shafts .

2 - DISMANTLING

remove the 5th driven gear (1) and the bearing (2) using a press and tool [2] pressing under the 4th speed gear (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 :

• the 5 speed driven gear (1)
• the bearing (2)
• the 4th and 3rd speed driven gear (3)
• the 2nd speed driven gear (4) and its thrust collar (5)

Mark the position of the hub in relation to the synchroniser .

Remove the sliding gear and its hub (6) .

Remove :

• the 1st speed driven gear (7)
• the needle thrust bearing (8)

Remove the locking ring (9) using circlip pliers and, if necessary, a set of feeler gauges .

Protect the end of the shaft with the nut (10) .

remove the bearing (11) using a press and tool [2] .

3 - ASSEMBLY

Always renew :

• the bearings
• the lock washers
• 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 bearing (11), groove to the top, using tool [5] .

Fit :

• the bearing locking ring (9)
• the needle thrust bearing (8)
• the 1st speed driven gear (7)
• the sliding gear and its hub (6) according to the marks made during removal ; the sliding gear tooth leads are towards the 2nd speed gear
• the thrust washer (5)
• the 2nd driven gear (4)
• the 3rd/4th speed driven gear (3)

refit the bearing (2), groove to the top, using tool [4] .

Refit the 5th driven gear (1) (small collar of the gear on the bearing side) .

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 .