the stripdown



The first thing you will want to do is remove the gearbox selector unit, remove the 5 13mm bolts
DSC01087.jpg
after removal
DSC01088.jpg

After this you will need to remove 7 10mm bolts that hold the tin cover on at the end of the gearbox
DSC01081.jpg

Now you will have to knock out the locking tab on the nuts at the end of each of the shafts and take the nuts off
DSC01082.jpg
DSC01089.jpg

Now remove the 10mm bolt that holds the sector onto the selector shaft
DSC01083.jpg

With the bolts and nuts removed pop a screw driver under 2 sides of one of the gears and lift the gear off its splines
DSC01092.jpg
try not to lose the small springs and round rods that hold the selector in place

This picture shows where spring is round rod would be on the end of this
DSC01091.jpg

Now remove the 4 5mm counter sunk cap head bolts with the shake proof washers on them
and lift the plate off
DSC01096.jpg

Holding the bearing's in place is 2 spring clips, remove them
DSC01097.jpg


Now time to remove a total of 12 13mm bolts that hold the gear casing to the bell housing and a drive-shaft seal plate onto the differential housing
DSC01100.jpg
DSC01102.jpg
plate removed
DSC01103.jpg
o-ring on the back of the plate, one item to take note of
DSC01104.jpg

Now to remove the bolt for the reverse idler shaft (13mm)
DSC01105.jpg

then pull off the casing, trying to keep it level, you can tap the top of each shaft as the bearings would be sticking on abit and it will come straight off
DSC01106.jpg

remove the 2 13mm bolts that hold the reverse gear selector on
DSC01109.JPG

lift the reverse gear up slightly then turn the shaft and pull it up and it will come out
DSC01108.jpg

This is the reverse selector
DSC01110.jpg

This is the little bar that line the hole with the hole in casing for the reverse gear
DSC01111.jpg

you can now remove the selector unit for the man gears, nothing holding them on just lift up and pull out
DSC01112.jpg
DSC01113.jpg

Now you should have a gearbox like this
DSC01115.jpg

Simply pull both shafts out together and place them somewhere
DSC01116.jpg

lay shaft
DSC01117.jpg

main shaft
DSC01118.jpg

Now remove 4 13mm bolts and 4 15mm bolts that hold the differential unit on and remove from bell housing
DSC01120.jpg

arrow points out a magnet for collecting metal debris
DSC01121.jpg

The differential
DSC01123.jpg
DSC01124.jpg

from left to right (arrows)
spacer, bearing runner, tapered roller bearing
DSC01125.jpg

planet and sun gears
DSC01127.jpg

Full view off 2 differentials, both with bonded crown wheels, i was after a bolted :(
DSC01128.jpg

Hope this helps you

Ash
Previous page: Overview