B2CJ0XK1 - 406D9 ML5T GEARBOX
DISMANTLING - ASSEMBLY SYNCHRONISER
1 - DISMANTLING
WARNING : mark the relative positions of the hub and sleeve if these parts are to be re-used .
Separate the sleeve from the hub in a container to facilitate retrieval of the balls, springs and fingers .
2 - ASSEMBLY
2 - 1 - SYNCHRONISER - (1ST - 2ND)
WARNING : position the face of the synchroniser hub which receives the stop ring to side (G) .
NOTE : repeat the following operations for each assembly .
PLACE TOOL [13] ON THE SYNCHRONISER .
Position the paint mark (F) opposite one of the spring housings, matching the shape of the cut-out (H) in the tool to that in the synchroniser hub .
MODERATELY TIGHTEN THE BOLT [13B] RETAINING THE SYNCHRONISER HUB .
Fit in the following order :
LOCK THE ASSEMBLY WITH THE PUSHER [13a] (The notch in the finger (7) must be turned downwards) .
Fit the other assemblies :
Lay the synchroniser sleeve flat .
Make a paint mark (I) opposite one of the synchroniser ring housings .
OFFER UP THE HUB (9)/TOOL [13] ASSEMBLY ABOVE THE SYNCHRONISER SLEEVE .
Align the paint marks "F,I" on the tool and the synchroniser sleeve .
SLACKEN THE BOLT [13b] .
Insert the synchroniser hub in the synchroniser sleeve .
2 - 2 - SYNCHRONISER (3RD-4TH)
PLACE TOOL [16] ON THE SYNCHRONISER .
Proceed in the same way as for the 1st/2nd synchroniser .
NOTE : the synchroniser sleeve can be fitted in either direction .
2 - 3 - SYNCHRONISER : 5TH
PLACE TOOL [16] ON THE SYNCHRONISER .
PLACE THE BOSS J OPPOSITE A PAINT MARK ON THE TOOL [16] .
MODERATELY TIGHTEN THE BOLT [16B] RETAINING THE SYNCHRONISER HUB (10) .
Fit in the following order :
LOCK THE ASSEMBLY WITH THE PUSHER (16A); THE NOTCH IN THE FINGER (7) MUST BE TURNED UPWARDS .
Make a paint mark (K) opposite one of the synchroniser ring housings .
OFFER UP THE HUB (10)/TOOL [16] ASSEMBLY ABOVE THE SYNCHRONISER SLEEVE (11) .
Align the paint marks (K) - (I) on the tool and the synchroniser sleeve .
SLACKEN THE BOLT [16b] .
Insert the synchroniser hub in the synchroniser sleeve .
3 - COMPLEMENTARY OPERATION(S)
Assembly : Output shaft .
Refitting :
Assembly : Gearbox .