B2CG53K1 - 206 MA GEARBOX

DISMANTLING - REASSEMBLING OUTPUT SHAFT

1 - SPECIAL TOOLS

reference	description	reference	reference
[1]	universal extractor	FACOM U53T

reference	description	reference	reference
[2]	tool for fitting the output shaft bearing at the 4th speed end	(-).0317-B	7.101T-B
[3]	stop ring drift	(-).0317-P	4508T-V
[4]	spacer washer	(-).0317-Q	4508T-U
[5]	tool for fitting the output shaft bearing at the 1st speed end	(-).0317-E	7.101T-E
[6]	fitting tool for the output shaft circlip	(-).0317-R	4508-T.T

2 - PRELIMINARY OPERATIONS

Dismantling : Gearbox .

Removal : Gearbox casing .

Removal : Input, output shafts and differential .

3 - DISMANTLING

Remove the bearing (3) using the extractor [1] .

Remove :

the washer (4)
the 4 speed driven gear (5)
the synchroniser ring (6) (4 th gear)
the 3rd/4th synchroniser ring
the synchroniser ring (8) (3 th gear)

WARNING : do not dismantle the synchroniser (7) to avoid ejection of the balls and springs .

Drift out the stop ring (9) using tool [3] .

Remove :

the 3 speed driven gear (10)
the stop ring (11)
the 2 speed driven gear (12)
the synchroniser ring (13) (2 th gear)
the 1st/2nd synchroniser (14)
the synchroniser ring (15) (1st)
the stop ring (16)
the 1st speed driven gear (17)
the stop ring (18)
the lubrication nipple (19)

WARNING : do not dismantle the synchroniser (14) to avoid ejection of the balls and springs .

Remove the bearing (20) .

4 - ASSEMBLY

WARNING : bearings removed must not be re-used; lubricate the components as they are refitted; check that the shaft bearings are in perfect condition, no knock or scratch marks; match up the marks made during removal; use parts which are clean and free from faults .

Fit the new bearing (20) using the tool [5] and the distance piece [4] .

Fit :

the new stop ring (18)
a new plastic lubrication nipple (19)

WARNING : position the lugs (A) on the rings of the fingers (B) of the synchronisers (14) and (7) .

Fit :

the 1st speed driven gear (17)
the new stop ring (16)
the synchroniser ring (15) (1st)
the 1st/2nd synchroniser (14), groove (C) to the bottom
the synchroniser ring (13) (2nd)
the 2 speed driven gear (12)
the new stop ring (11)
the 3 speed driven gear (10)
the new stop ring (9)
the synchroniser ring (8) (3rd)
the 3rd/4th synchroniser (7), groove (D) to the top
the synchroniser ring (6) (4th)
the 4 speed driven gear (5)
the washer (4)

WARNING : do not press on the lubrication nipple, and do not exceed 2 tonnes against the stop .

Fit the new bearing (3), groove (E) towards the top .

5 - COMPLEMENTARY OPERATION(S)

WARNING : observe the cleaning and refitting conditions .

Refitting : Input, output shafts and differential .

Refitting : Gearbox casing .

Reassembling : Gearbox .