B2CG53K1 - 206 MA GEARBOX

DISMANTLING - REASSEMBLING OUTPUT SHAFT

1 - SPECIAL TOOLS

reference | description | reference | reference
--- | --- | --- | ---
[1] | universal extractor | FACOM U53T

reference | description | reference | reference
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[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 .