B2CG54K1 - 206 MA GEARBOX

DISMANTLING - ASSEMBLY SYNCHRONISERS

1 - SPECIAL TOOLS

2 - PRELIMINARY OPERATIONS

Dismantling : Gearbox .

Removal : Gearbox casing .

Removal : Input, output shafts and differential .

Dismantling : Output shaft .

3 - IDENTIFICATION OF SYNCHRONISERS

3 - 1 - CONVENTIONAL SYNCHRONISER : 1ST/2ND

(1) Sleeve .

(2) Hub .

(3) Ball .

(4) Spring .

(5) Finger .

3 - 2 - IMPROVED 1ST/2ND SYNCHRONISER

(6) Sleeve .

(7) Hub .

(8) Ball .

(9) Finger .

(10) Ball seat .

(11) Spring .

3 - 3 - CONVENTIONAL SYNCHRONISER : 3RD/4TH/5TH

(12) Sleeve .

(13) Hub .

(14) Ball .

(15) Spring .

(16) Finger .

4 - DISMANTLING

IMPERATIVE : 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 .

5 - ASSEMBLY

5 - 1 - CONVENTIONAL SYNCHRONISER : 1ST/2ND

Direction of assembly of the 1st/2nd gear synchroniser, with the groove (A) on the hub directed to the same side as the fork location (B) on the sleeve .

On reassembly, observe :

• the marks made on dismantling
• the relative positions of the notches (C) in the sleeve and (D) in the hub

Assemble the two parts .

For each of the three devices :

• position and support the finger (5)
• insert the spring (4) into the finger and fully into the hub at (D)
• place the ball (3) on the spring
• press on the ball (3) to compress the spring (4) and insert it in the sleeve (1)

5 - 2 - IMPROVED 1ST/2ND SYNCHRONISER

Direction of assembly of the 1st/2nd gear synchroniser, with the groove (E) on the hub directed to the same side as the fork location (F) on the sleeve .

Respect the marks made on dismantling .

Position the notch (G) on the hub (7) opposite hole no. 1 of the tool [1] .

Position :

• the spring (11)
• the ball seat (10)

With a pin punch, press on the ball seat (10) .

Fit the finger (9) .

Insert the ball (8) in the hole .

Press on the ball (8) with the pin punch .

Turn the hub in the tool :

• to retain the arming device in place
• to position the second dimple (B) opposite hole no.2

Fit the two other devices .

IMPERATIVE : follow the order of the numbers engraved on the tool [1] .

Fit :

• the sleeve (6) with the toothed surface on the bench
• the hub and tool assembly on the sleeve observing the marks made on dismantling

Holding the tool [1] on the sleeve, insert the hub using tool [2] .

Remove the tools .

5 - 3 - CONVENTIONAL SYNCHRONISER : 3RD/4TH/5TH

Direction of assembly of the 3rd/4th gear synchroniser, groove (H) on the hub opposite the fork location (I) on the sleeve .

Direction of assembly of the 5th gear synchroniser: the hub is symmetrical, it has no direction of assembly in relation to the sleeve .

On reassembly, observe :

• the marks made on dismantling
• the relative positions of the notches (J) in the sleeve and (K) in the hub (13)

Assemble the two parts .

For each of the three devices :

• position and support the finger (16)
• insert the spring (15) into the finger and fully into the hub at (K)
• place the ball (14) on the spring
• press on the ball (14) to compress the spring (15) and insert it in the sleeve (12)

6 - COMPLEMENTARY OPERATION(S)

WARNING : observe the cleaning and refitting conditions .

Assembly : Output shaft .

Refitting : Input, output shafts and differential .

Refitting : Gearbox casing .

Assembly : Gearbox .