B2CG58K1 - 206 MA GEARBOX

REFITTING INPUT, OUTPUT SHAFTS AND DIFFERENTIAL

1 - PRELIMINARY OPERATIONS

Reassembling : Clutch housing .

2 - REFITTING

IMPERATIVE : clean the threads of the clutch housing using a tap, and the threads of the reused bolts using a die .

Fit :

• the differential (1)
• the spring (2)
• the reverse fork locking finger (3)

Coat the contact surface of the intermediate plate (4) and that of the clutch housing with E12 .

Insert the selection fork in the passage (A) in the intermediate plate .

Fit the intermediate plate .

WARNING : unstrengthened gearboxes with the intermediate plate secured in production by 9 bolt(s) must be refitted with 11 bolt(s) in service .

Fit the bolts and tighten them to 5 da.Nm .

WARNING : remove the excess adhesive from the bearing seat and the fork shaft bores after tightening the plate bolts .

Insert the forks in the synchroniser sleeves .

Couple the output shaft with the input shaft .

Fit the assembly into the casing .

Insert the engagement finger (5) in the interlock key (6) .

1st fitting :

• fit the assembly by simultaneously engaging the finger in the fork shaft lugs (B) and the frame (C) in the selection shaft fork (D)

2nd fitting :

• refit the assembly by simultaneously engaging the finger on the fork shaft lugs (E)

Fit :

• the spring (7) and its two thrust cups (8) (depending on the fitting)
• the new shaft seal (9), pre-greased on the inside
• the engagement shaft (10)

WARNING : the engagement finger and the shaft are drilled together; their matching must be maintained .

Secure the finger with a new solid ribbed pin (11) .

Engage the reverse fork (12) in the yoke .

Press gently on the reverse fork (12) and insert its shaft (13) fully home .

Fit :

• the reverse sliding gear (14)
• the idler shaft (15)
• the plastic spacer (16)

WARNING : rotate the shaft until the step (F) falls into its housing .

IMPERATIVE : on gearboxes fitted with a reverse gear brake, check the presence of the circlip (17) and the reverse brake spring (18) on the 1st/2nd gear fork shaft .

3 - COMPLEMENTARY OPERATION(S)

WARNING : observe the cleaning and refitting conditions .

Refitting : Gearbox casing .

Reassembling : Gearbox .