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32 643 - AN - 02.2002

50 21 008 347

32 643

GEARBOX VEHICLE

MIDLINER 4x2 / 4x4MIDLUM 4x2 / 4x4

PA 210EATON 4106 / 5206 TRM 180

TRM 200GBC 180

PREMIUM

directory

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32.6

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Section 1 Generalities1/1 Model designation1/2 Technical data1/3 Lubrication1/4 Recommended lubricants1/5 Recommended tightening torques1/7 Disassembly precautions and inspection of fast wearing parts1/9 Reassembly precautions

1/10 Gear end float

Section 2 General description2/1 Features2/2 Gear change pattern2/2 Power flow diagrams

Section 3 Gearshift control3/2 Remote control - Exploded view3/3 Remote control disassembly

3/4 Remote control reassembly

Section 4 Gearbox overhaul4/2 Gearbox casing - Exploded view4/3 Gearbox casing disassembly4/8 Input shaft disassembly4/9 Input shaft reassembly

4/10 Layshaft disassembly4/11 Layshaft reassembly4/13 Main shaft disassembly4/14 Main shaft assembly - Exploded view

4/17 Main shaft reassembly4/25 Selector shaft disassembly4/26 Selector shaft reassembly4/27 Gearbox casing reassembly4/36 Rear closing plate reassembly

Section 5 Double cone synchronizers5/2 Main shaft disassembly5/9 Main shaft reassembly

5/22 1st & 2nd speed synchronizer unit

Section 6 Tools6/1 Tools

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Generalities

Model designation

Example: FSO - 4106 A

FS Standard prefixO Overdrive4 Rated torque in ft.lbs1 Series 106 Number of forward gearsA Standard ratio setB, C Other ratio sets

Gearbox identification

All gearboxes are fitted with an identification plate on the left-hand side of the front half-casing, showing:

1. Gearbox serial number.2. Gearbox model.3. Manufacturing date code number.4. Gearbox specification number.

The gearbox specification number is unique to each customer and gives precise details of the gearboxdesign level. This number must be quoted when ordering spare parts.

There are currently two design levels of the 4106 gearbox. Each level is identified by the specificationnumber:

Y 04000Y 04100

The middle digit denotes the design level.

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MODEL 4106

Max. input torque FS-4106A 640 Nm 65 ft. lbsFS-4106B 650 Nm* 66 ft. lb

for engine performance up to 134 kW 182 hp

Weight (1) 117 kg

Length (2) 555 mm

Oil capacity (4)Horizontal mounting 6.5 litresVertical mounting 7.5 litres

Clutch housing SAE Standard

Power take-off ports Left side (vertical mounting)Bottom right (horizontal mounting)SAE 6 bolt facing plus extendedlayshaft for Eaton PTO

PTO driving gears (3) Rotation to enginedriven from the reverse idler gear at : Engine speed xFS-4106A (standard ratio) 0.226 sameFS-4106B (alternative ratio) 0.271 sameFSO-4106B (overdrive ratio) 0.336 same

driven from layshaft front gear at : Engine speed xFS-4106A (standard ratio) 0.434 oppositeFS-4106B (alternative ratio) 0.519 oppositeFSO-4106B (overdrive ratio) 0.644 opposite

Gear Standard % Standard % Overdrive %ratio staging ratio staging ratio staging

6 1.00 1.00 0.79 38 30 26

5 1.38 1.30 1.00 45 44 35

4 2.00 1.87 1.35 55 50 55

3 3.10 2.80 2.09 69 57 69

2 5.25 4.38 3.53 72 72 72

1 9.03 7.54 6.08

Bak 8.07 6.74 5.43

(1) Including output coupling, low remote control; excluding clutch housing.(2) Front face of gearbox casing to rear face of output flange.(3) Recommended backlash: from 0.15 to 0.25 mm.(4) Oil capacity without PTO.* Higher torques: subject to approval by Eaton.

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Generalities

Technical data

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Correct oil level

Before checking the oil level or refilling, thevehicle should be on level ground.Make sure the oil level is flush with the filler port.

Draining the oil

Drain the gearbox while the oil is hot.To drain the oil, remove the drain plug at thebottom of the casing.Clean the drain plug before refitting.

Refilling with oil

Clean the surrounds of the filler plug.Fill the gearbox until the oil is flush with the fillerport.The exact amount of oil depends on theinclination of the gearbox.

In every instance, fill until the oil is flush with thefiller port.Do not overfill - this causes oil to be forced out ofthe casing past the main shaft and input shaftseals.

Adding oil

It is recommended that different types and brandsare not intermixed because of possibleincompatibility.

Operating temperature

It is important that the gearbox operatingtemperature does not exceed 120 C (250 F) foran extended period of time. Operatingtemperatures above 120 C cause breakdown ofthe oil and shorten gearbox service life.

Any combination of the following conditions cancause operating temperatures in excess of120 C:

1. Consistent operation at road speeds below 32km/h (20 mph).

2. High engine speeds.3. High ambient temperature.4. Restricted air flow around gearbox.5. Exhaust system too close to gearbox.6. Engine operation at maximum power in

overdrive.

7. High power PTO operation for extensiveperiods while stationary.

High operating temperatures may require morefrequent oil changes.

Towing

When towing the vehicle, the propeller shaft mustbe disconnected between the gearbox and thedrive axle.

Generalities

Lubrication

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Generalities

Recommended lubricants

Oils

Choice of lubricants according to operating temperature:

Renault Trucks Oils

Oil Temperature rangeMV3 20 W 30 da 20C to + 30CMV3 25 W 40 da 10C to + 40CEP 90 da 10C to + 30CEP 80 W da 20C to + 20CSUPERTRANS EPX da 10C to + 50C

International standards

Oil Mil-L API Temperature rangeSAE 30 2104 E CE/SF da 20C to + 30CSAE 40 2104 E CE/SF da 10C to + 40CSAE 90 2104 D GL 4 da 10C to + 30CSAE 80 W 2104 D GL 4 da 20C to + 20CSAE 80 W 90 2104 D GL 4 da 10C to + 30CSAE 80 W 85 W 2104 D GL 4 da 20C to + 25C

DO NOT use oil additives, friction modifiers or synthetic lubricants.

CONSUMABLE PRODUCTS

Industrial reference Automotive reference Bottle RENAULT TRUCKSref N

Loctite 242 Thread locking compound 24 ml 50 00 336 94960 ml 50 00 336 950

Loctite 270 Adhesive sealant 24 ml 50 00 336 94760 ml 50 00 336 948

Loctite 518 Joint sealant 25 ml 50 00 630 985

Loctite 648 Flange sealant 240 ml 50 00 630 037

Activator T 747 Activator 165 ml 50 00 630 036

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Screws and nuts

1. Clutch housing12 studs - M12 screw-thread - 59 Nm (43 ft.lbs) minimum. Installed with Loctite 242.

2. Clutch housing12 nuts - M12 screw-thread - 69 to 78 Nm (51 to 58 ft.lbs). With plain washers and spring washers.

3. Clutch housing12 cap screws - M12 screw-thread - 69 to 78 Nm (51 to 58 ft.lbs). With plain washers and spring washers.

4. Front PTO cover06 cap screws - M10 screw-thread - 35 to 39 Nm (25 to 29 ft.lbs).

5. Selector block tapered lockscrew1 screw - M10 screw-thread - 35 to 39 Nm (25 to 29 ft.lbs). Patchlock or screw-threads coated with Loctite 242.

6. Main half-casings15 cap screws with plain nuts - M10 screw-thread - 51 to 58 Nm (38 to 43 ft.lbs). With plain washers under cap screws and nuts.

7. Main half-casings3 cap screws - M10 screw-thread - 51 to 58 Nm (38 to 43 ft.lbs). Plain washers.

8. Remote control housing end cover4 cap screws - M8 screw-thread - 20 to 24 Nm (15 to 18 ft.lbs). Spring washers.

9. PTO/reverse idler gear cover6 cap screws - M10 screw-thread - 35 to 39 Nm (25 to 29 ft.lbs).

10. Output shaftLocknut - M33 screw-thread - 490 to 588 Nm (362 to 434 ft.lbs). With nylon locking insert.

11. Remote control housing4/6/8 cap screws - M10 screw-thread - 35 to 39 Nm (25 to 29 ft.lbs). Plain washers and spring washers.

12. Overdrive selector fork pivot2 cap screws - M10 screw-thread (with spring washers) - 20 to 24 Nm (15 to 18 ft.lbs).

Generalities

Recommended tightening torques

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Screws and nuts

1. Remote control shaft lever1 cap screw and nut - M8 screw-thread - 20 to 27 Nm (15 to 20 ft.lbs). With spring washer.or1 cap screw and nut - M10 screw-thread - 35 to 39 Nm (55 to 29 ft.lbs). With spring washer.

2. Selector shaft detent cover2 cap screws - M8 screw-thread - 20 to 24 Nm (15 to 18 ft.lbs). With spring washer.

3. Oil filler plugM24 screw-thread - 32 to 37 Nm (24 to 27 ft.lbs).

4. Layshaft front bearing cover4 cap screws - M12 screw-thread - 69 to 78 Nm (51 to 58 ft.lbs). With spring washer.

5. Input shaft front bearing cover

5 cap screws - M10 screw-thread - 35 to 39 Nm (25 to 29 ft.lbs). With spring washer.

6. Remote control housing detent cover2 cap screws - M8 screw-thread - 20 to 24 Nm (15 to 18 ft.lbs). With lockwasher.

7. Oil drain plug (magnetic)M24 screw-thread - 32 to 37 Nm (24 to 27 ft.lbs).

8. Speedometer drive pinion adapterM22 screw-thread - 20 to 27 Nm (15 to 20 ft.lbs). With copper washer.

9. Speedometer housing4 cap screws - M10 screw-thread - 35 to 39 Nm (25 to 29 ft.lbs). With plain washer and spring washer.

10. Layshaft rear bearing cover (rear PTO)4 cap screws - M12 screw-thread - 69 to 78 Nm (51 to 58 ft.lbs). With spring washer.

11. Reverse lamp switchM16 screw-thread - 16 to 22 Nm (12 to 17 ft.lbs).

Generalities

Recommended tightening torques (continued)

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Generalities

DisassemblyprecautionsIt is assumed in the detailed disassemblyinstructions that the lubricant has been drained

and the necessary linkages and air lines (if fitted)have been removed from the chassis.Removal of the gearshift remote control housingassembly is included in the detailed instructions.However, this assembly may also be removedfrom the gearbox before removing the unit fromthe vehicle.Follow each procedure closely in eachsection, making use of both the text and thepictures.

1. Bearings - Carefully wash and relubricate allbearings as removed and protectively wrap untilready for use. Remove bearings with pullersdesigned for that purpose.

2. Assemblies - When disassembling thevarious assemblies, such as main shaft, layshaftand remote control housing, lay all parts on aclean bench in the same sequence as removal.This procedure will simplify reassembly andreduce the possibility of losing parts. Whenpulling off synchronizer hubs, follow theprocedures detailed in Disassembly, using asuitable puller of adequate capacity. Failure toadhere to the recommended procedures maycause irreparable damage.

3. Circlips - Remove circlips and snap rings withpliers designed for that purpose. New selectivecirclips must be fitted as specified inReassembly.

4. Input shaft - The input shaft can be removedwithout removing the layshaft or the main shaft.

Take care not to misplace or lose the main shaftspigot bearing.

5. Cleanliness - Provide a clean place in whichto work. It is important that no dirt or foreignmatter enters into the unit during repairs. Theoutside of the unit should be carefully cleanedbefore commencing disassembly. Dirt is abrasiveand can damage bearings.

6. Press fitting - Apply force to shafts, housings,etc with restraint. Movement of some parts is

restricted. Do not apply force after the part beingdriven stops solidly. Use soft hammers for alldisassembly work.Do not use pry bars or chisels to separate half-casings or irreparable damage may be caused.

Inspection of fastwearing partsBefore reassembling the gearbox, individual partsshould be carefully checked and damaged parts

discarded. They must be replaced. Thisinspection procedure should be carefully followedto ensure maximum service life from the rebuiltunit.The cost of a new part is generally a smallfraction of the total cost of downtime and labour,should the use of a questionable part makeadditional repairs necessary before the nextregularly scheduled overhaul.Recommended inspection procedures are set outin the following checklist:

A. Bearings

1. Wash all bearings in clean solvent. Checkrollers and races for pitting and crumbling.Replace damaged bearings.

2. Lubricate undamaged bearings and check endplay and radial play. Replace bearingspresenting excessive play.

3. Check the fits of bearings in housing bores. Ifthe outer races turn too freely in the bores, thehousing should be replaced. Check housingbores for signs of wear prior to taking suchaction. Only replace the housing if wear is due tobearing spin.

B. Gears

1. Check gear teeth for tooth face pitting.Gearwheels with pitted teeth should be replaced.

Check the reverse gear dog clutch engagementteeth for freedom from damage.

2. Check internal bearing surfaces for wear andeffects of overheating.

3. Check gear end play. Where excessive playis found, check both gearwheel and hub forexcessive wear.Maintain the specified end play on main shaftforward gears.

C. Bearing sleeves - Main shaft

1. Sleeves presenting scoring, pitting or signs ofoverheating or wear must be replaced.

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D. Synchronizer assemblies1. Check to ensure that all splines are free fromexcessive wear.

2. Check that the dog clutch engagement teethon sliding sleeves, synchronizer flanges andsynchronizer rings are free from flaking andburrs.

3. Check that synchronizer cone rings are notexcessively worn or show signs of overheating.Check that the clearance between synchronizer

ring and synchronizer flange is between 1.9 mmmaximum and 0.5 mm minimum.

4. Replace springs, plungers and rollers.

E. Splines

1. Check splines on all shafts for wear. Ifsynchronizer hubs, output drive flange or clutchhub have worn into the sides of the splines,shafts in such condition must be replaced.

F. Thrust washers1. Check the surfaces of all thrust washers.Washers presenting scoring or reduction inthickness should be replaced.

G. Reverse idler gear

1. Check bearings and shaft for wear due to theaction of roller bearings.

H. Clutch release parts

1. Check clutch release parts, yoke and bearingcarrier. Check pedal shafts. Replace worn shaftsand bearings.

I. Gear selector shaft assembly

1. Check forks and keys for wear at points ofcontact. Replace worn parts.

2. Check forks for excessive and uneven wear.Replace worn forks.

3. Check selector block lockscrews. Lockscrews

with worn taper must be replaced.4. Check condition and fit of selector key andinterlock key in gearshift shaft. Worn or damagedkeys must be replaced.

J. Gearshift remote control1. Check spring tension on cross shaft. Replacetension springs if the shaft moves too freely.

2. If the housing is dismantled, check crossshaft, inner lever and bearing bushes for wear.Replace worn parts.

3. Check all seals and locating journals.Replace worn parts.

K. Bearing covers

1. Check covers for wear due to bearing thrust.Replace covers worn or scored by thrust due tobearing outer races.

2. Check cover bores for wear. Replaceexcessively worn covers.

L. Oil return seals

1. Check oil seal in front bearing cover fordamage and wear. Replace if necessary.

2. Check oil seal in speedometer housing fordamage or wear. Replace if necessary. Replacegrit shield if worn or loose on flange.

3. Check oil seal journals for wear and replace ifworn or grooved.

M. O-rings

1. Replace all O-rings.

Generalities

Inspection of fast wearing parts (continued)

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Make sure that the interiors of all housings areclean. It is important that dirt be kept out of thegearbox during reassembly. Dirt is abrasive andcan damage the polished surfaces of bearingsand washers. Observe certain precautions, aslisted below, during reassembly.

1. Gaskets - Use new gaskets only whereindicated (neutral detent cover and remotecontrol housing covers). In all other locations,ensure that mating surfaces are clean andundamaged and apply a continuous bead ofLoctite 518 Flange Sealant to one face only. Donot apply excessive sealant or allow it topenetrate into the bearings.

2. Threaded hardware - Use thread sealant(Loctite 641) on all screws. The correspondingtorque loadings are to be found in

Recommended tightening torques for screwsand nuts.

3. O-rings - Lubricate all O-rings lightly withsilicone lubricant.

4. Initial lubrication - Lubricate bearings withgearbox oil during reassembly.

5. End play - Maintain the end float of main shaftgears as detailed in the chart on the followingpage.

6. Bearings - The use of flanged bearingmandrels is recommended for the installation ofbearings. Such drivers apply equal force to bothbearing races, preventing damage to balls andraces and maintain correct bearing alignmentwith shaft and bore. Tubular type mandrels, ifused, will apply force to the inner race only.Heating the bearing inner tracks will aidinstallation.

7. Output shaft drive flange - Tighten the nut atthe correct torque.

8. Synchronizer hubs - All synchronizer hubsare an interference fit on the main shaft splinesand must be heated at approximately 85 C(180 F) before installation.

9. Layshaft - The layshaft gears are a shrink

and press fit on the layshaft body. Thegearwheels must be heated to 150 C (300 F)before assembly.

10. Prior to fitting a flange (or yoke), ensure thatthe seal track is not grooved, scored or pitted. Ifin doubt, it must be replaced.

11. All synchronizer flanges are now fitted to thegears using Loctite. Loctite 648 + Loctite T 747Activator are used. It is recommended to mix thesealant and activator before commencing

reassembly to allow sufficient time for the Loctiteto cure.

Generalities

Reassembly precautions

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Generalities

Gear end floatAll dimensions in millimetres (mm)

Gear5th

(6th overdrive) 4th 3rd 2nd 1st Reverse

Low limitHigh limitRange

0.310.530.22

0.350.480.13

0.350.480.13

0.350.480.13

0.400.570.17

Slidinggear

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General description

Features

The Eaton 4106 gearbox has six forward speeds and is one of a new family of synchromesh gearboxes.

It has a simple shift pattern using a unique single rail selector mechanism.

The gearbox may be mounted vertically or horizontally and in both positions the gear change remotecontrol may be to the right or to the left.

The synchronizer assemblies are of the baulk ring type with the gear ring cones manufacturedseparately from the gears. This allows the synchronizer rings and flanges to be replaced without needto replace the gears themselves. Reverse gear is engaged by sliding the reverse gear on the mainshaft into mesh with a dog clutch ring splined to the main shaft.

Vertical mountingControl to left

Vertical mountingControl to right

Horizontal mountingControl to left

Horizontal mountingControl to right

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General description

Gear change pattern

Simple shift pattern with the mechanism biasedin neutral between 3rd and 4th gears.

Power flow diagrams - direct drive top gear version

(R)

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Gearshift control

Remote control

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Gearshift control

Remote control - Exploded view

Sequence N Description

2700-0103 Gearkassehus2700-0106 Ring2700-0109 Pakning2700-0112 Tvrgende aksel2700-0115 Den indvendige koblingsgaffel2700-0136 Rillestift2700-0121 Fjederholder2700-0124 Fjeder2700-0127 Fjeder (kun venstre)2700-0130 Fjederholder2700-0139 Dksel2700-0142 Pakning2700-0148 Skrue, M82700-0151 Fjederskive, M82700-0154 Stempel, bag

2700-0157 Lsefjeder, bag2700-0160 Lsedksel2700-0163 Pakning til lsedksel2700-0166 Skrue, M82700-0169 Fjederskive2700-0171 Prop2700-0173 Snfteventil2700-0175 Beskyttelsesmuffe2700-0177 Ydre hndtag2700-0181 Bolt, M10 x 502700-0183 Mtrik, M10 x 1,02700-0118 Lsering2700-0133 Lsering2700-0185 Skive2700-0187 Stift

2700-0189 Prop eller

2700-0191 Skive

HousingBushOil sealCross shaftInner striking leverGrooved pinSpring retainerSpringSpring (LH only)Spring retainerEnd coverGasketScrew, M8Spring washer, M8Plunger-reverse

Spring-reverse detentDetent coverGasket, detent coverScrew, M8Spring washer, M8PlugBreatherRubber bootRouter leverBolt, M10 x 50Nut, M10 x 1.0CirclipCirclipWasherPin

Plug orNeutral switchWasher

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1. Ensure that neutral is selected and remove theremote control assembly from the gearbox.

4. Remove the four cap screws and lift off the endcover.

2. Remove the outer gear change lever and therubber boot. Remove the neutral switch and thepin (if fitted).

Note: The position of the lever is marked on theshaft. Check before removal.

5. Remove the circlip from the shaft and removethe spring retainer.

3. Remove the reverse detent plunger cover andpull out the spring and the plunger.

6. Withdraw the booster spring, bias spring andinner retainer.

A. Remote control disassembly

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7. Reverse the position of the housing andcarefully drive out the expansion plug.

1. If necessary:Take out the bearing bushes. Use tool N001.Press fit new bushes. (Use the removed part as apusher).

8. Reverse the position of the housing. Align thegrooved pin in the inner lever with the expansionplug hole and carefully drive out the pin.

2. Replace the oil seal.Install the new seal, using a tube.

9. Remove the shaft and the inner lever. 3. Install the inner lever, with the long plaingroove towards the front of the housing, andinstall the shaft from the right-hand side of thehousing.

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B. Remote control reassembly

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4. Align the inner lever on the shaft and install anew grooved pin.

Note: The inner lever should be supported whilstdriving the pin, to prevent damage to the bushes.

7. Fit the outer circlip on the shaft.

5. Fit the inner circlip on the shaft. Install thesmaller spring retainer.

8. Fit a new gasket and secure the end cover tothe housing. Tighten at the correct torque(20 to 24 Nm).

6. Insert the springs and the outer retainer.

Note: Right-hand drive versions need one largeretainer whereas left-hand drive versions use onelarge (outer) and one small (inner) retainer.

9. Install the reverse detent plunger and the

spring and fit the cover (using a new gasket).Tighten the cap screws at the correct torque(20 to 24 Nm).

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10. Fit the rubber boot on the housing. Align theouter lever with the setting mark on the shaft. Fitthe pinch bolt and tighten at a torque of 35 to39 Nm.

11. Fit the breather. Install the pin and the neutralswitch. Tighten at the correct torque (15 to 22 Nm).Apply sealant and install a new expansion plug.

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Gearbox overhaul

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Gearbox casing

Exploded view

178617881790

2055212021402150229722982301

Sequence N

1100-01011100-01031100-01051100-010720352040204520501230125012601700-07011700-07031700-07051700-07071700-07091700-07112060

206520702075170517101715172017701773177411761777177817791780

17821784

Description

Rear half-casingBushCore plugDowelOil troughDrive screwCoverScrewSpring washerCoverScrewSpring washerFront half-casingOil troughDrive screwBushCore plugDowel

CoverScrewWasherBoltScrewNutWasherCoverScrewWasherMagnetic drain plugRotation pinScrewWasherCopper washer

Neutral detent plungerSpring, detent

GasketScrewSpring washerPlugNeutral switch or WasherCup plugScrewWasherWasherOil filler plugCopper washer

Indicator switch, rev. light

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Caution: Drain the oil from the gearbox. Cleanand refit the drain and filler plugs.

Note: The gearbox illustrated in this section is astandard ratio vertically mounted unit. Theprocedure is the same for all gearboxes but thephysical size and number of teeth on some of the

gears will vary from those illustrated on overdriveand alternative ratio models.Horizontally mounted units have the remotecontrol on the side of the gearbox and differentfiller and drain plug positions.

3. Remove the speedometer drive pinion andhousing assembly or electronic tachometersender unit. Remove the reverse lamp switch.

1. Lift up the gearbox using a hoist.Install the unit on stand N002.Use tool N003.

4. Using a flange-holding wrench, remove theoutput drive flange retaining nut.Use tool N004.

5. Remove the output drive flange, using asuitable puller, if necessary. DO NOT use ahammer as there is risk of damaging the flange.Use tool N005.

A. Gearbox casing disassembly

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6. Ensure that neutral is engaged, then removethe remote control housing bolts. Use a soft-faced mallet to separate the housing from thegearbox.

9. Rotate the gear selector shaft anticlockwise(vertical mounting) or clockwise (horizontalmounting) to prevent the casing from fouling theselector block upon removal.

7. Remove the rear PTO cover. Using an 8 mmpunch, drive the reverse idler shaft grooved pinINWARDS until the end is approximately 12 mmbelow the face of the hole. Do not allow the pin tobottom against the shaft bore.

9A. On overdrive models, unscrew the capscrews retaining the two overdrive fork pivot pinsand remove the pins.

8. Remove the gear selector shaft detent plunger. 10. Remove the half-casing flange cap screwsand nuts. Note down the position of the shortercap screws fitted in the casing.

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11. Remove the cap screws securing the inputshaft cover and remove the cover. Remove theouter circlip from the input shaft bearing.

Reverse idler gear assembly.

12. Using a soft metal mallet, break the seal andseparate the front half-casing from the rear half-casing. DO NOT USE PRY BARS OR CHISELS.Lift off the front half-casing, leaving the inputshaft, complete with bearing, in place.

14. Using a sufficiently long drift, drive out thereverse idler gear shaft and expansion plug fromthe casing.

13. On overdrive models, disengage and removethe overdrive fork and pads. 15. Remove the reverse idler gear and the thrustwashers. Remove the bearings and spacers fromthe gear and the O-ring from the shaft.

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Sequence N Description

2600 Reverse idler gear shaft2603 O-ring2605 Reverse idler gear2610 Thrust washer2615 Needle roller bearing2620 Spacer2625 Pin

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16. Mount the special lifting tool on the main shaftunder the 5th/6th speed synchronizer. Lift up theshaft by approximately 20 mm. This allows thelayshaft to be lifted clear. Use tool N006.

19. Reverse the position of the rear half-casingon the stand and remove the cap screws securingthe speedometer housing. Note down thepositions of the different length cap screws.Remove the housing. If necessary, drive out theoil seal.

17. Lift off the input shaft complete with the 6thspeed flange. Lift out the layshaft. Remove the6th speed synchronizer ring.

18. Raise the hoist and lift out the mainshaft/selector shaft/forks assembly.

Carefully lower the assembly onto a clean benchand withdraw the special tool. Separate theselector shaft and forks from the main shaft.

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20. Remove the speedometer drive pinion ortachograph rotor and the bearing spacer from therear half-casing.

23. Drive out the outer cup from the layshaft rearbearing. Use tool N007.

21. Reverse the position of the casing on thestand and, using the special tool, drive out therear bearing from the main shaft. Do not allow thebearing to fall onto the floor.

24. Remove the front bearing retaining plate fromthe layshaft and the graded-fit spacer from thefront half-casing. Drive out the front bearing fromthe layshaft, using the special tool.Use tool N007.

22. Reverse the position of the casing on thestand and remove the layshaft rear bearing coverand bearing spacer.

25. Drive out the front bearing from the mainshaft. Use a tube.

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Note: Heat the bearing cage at a uniformtemperature of approximately 85 C (180 F) priorto assembly. This will greatly ease assembly and,in most cases, the bearing cage will be able to beslid over the shaft without forcing.

In the event of removal:Install the synchronizer flange (see page 4/12).

In the event of removal:Install the bearing cage.

4/9

C. Input shaft reassembly

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Note: To disassemble the gears on the layshaft,a 30/50 tonne hydraulic press will be required.In-service, it is only possible to replace the drivingand 5th speed gears.

2. If necessary, remove the bearing.

1. Support the shaft assembly and removes thegraded-fit circlip retaining the front taper rollerbearing.

3. For replacement only:Remove the 5th speed gear/bearing assembly.

Layshaft assembly

4/10

D. Layshaft disassembly

Sequence N13001310132018551856 to 1870

18811883 to 1889

DescriptionLayshaftTaper roller bearingDistance pieceTaper roller bearingCirclips

SpacerDistance pieces

To select :from 1856 to 1870

To select :from 1883 to 1889

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Note: During reassembly, in order to maintain theproper interference fit, it is necessary to chill theshaft body and any gears remaining attached to itat a temperature of - 10 C (15 F) and, at thesame time, to heat the new gearwheels at atemperature of 150 C (300 F) before quicklypress fitting the shaft. When pressing the shaft

into the gears, the pressing operation must not bestopped once it has been begun until the gearsare completely and firmly installed on the shaft.If two gears are being fitted, they should bepressed over the shaft separately and as quicklyas possible. The assembled shaft and gears mustremain under the press, with the appropriatepressure applied, until the temperature hasreturned to normal (some 10 minutes). 3. Heat the layshaft taper roller bearing inner

races at a temperature of 85 C (180 F). Supportthe shaft. The forward end facing upwards, andplace the heated cone/rollers assembly on the

shaft. Use a suitable mandrel to ensure that thebearing is fully home.

1. Chill the layshaft thoroughly and uniformly in afreezer or suitable refrigerator. Heat the gear(s)thoroughly at a temperature of 150 C (300 F).Use a Tempilstick crayon to make sure the gearsare at the required temperature. 4. From the available range of graded-fit circlips,

select the one that fits into the groove with theminimum of free play.

Circlips are available in the following sizes:

2. Place the 5th speed gear on the bed of thepress. Offer up the layshaft in the gear and pressfit the shaft into the gear, without delay. Repeatthis operation for the drive pinion. Allow to cool.

Reverse the position of the layshaft and fit theheated rear taper roller bearing inner race on theshaft. Use a suitable mandrel to ensure that thebearing is fully home.

4/11

E. Layshaft reassembly

Part N Thickness

8870370 2.12

8870371 2.07

8870372 2.02

8871536 1.97

8871537 1.92

8871538 1.87

8871539 1.82

8871540 1.77

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The synchronizer flanges are rendered integralwith the gears by the use of Loctite.

1. Apply a thin bead of Loctite 648 to the spline

teeth of the gear.Spray the splines of the synchronizer flange withLoctite T 747 activator.

1. Heat the gear/synchronizer flange assembly.

This operation softens up the thread-lockingcompound. Remove the flange from the gear.

Note: This also applies to the synchronizer flangeof the 6th speed gear on the input shaft. Use apress.

2. Allow the parts to cure for a minimum of twohours.Note: If the flange is not seated squarely, theprocedure must be repeated.

4/12

Assembly

Disassembly

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Note: All snap rings and the circlip on the shaftare graded for selective fit. Take care not to scorethe bearing surfaces of the main shaft whenremoving the snap rings.Note: The end float of the gears on the shaft isestablished during manufacture by machining thecomponents with very tight tolerances. Before

disassembly of the main shaft, the end floatsshould be checked to find out whether they enterwithin the recommended limits.Where excessive end float is found, it isnecessary to check the gears, main shaft,synchronizer hubs and bearing sleeve for wear.Refer to Inspection of fast wearing parts andreplace as required.

End float check

End float can be checked with the shaftassembled by using a dial gauge (as shownbelow).

1. Mount the shaft assembly in a vice fitted withsoft jaws. Carefully slide the 5th/6th speedsynchronizer sleeve upwards until the three rollersare clear of the groove in the sleeve. Remove

rollers, sleeve and three plungers and springsfrom the synchronizer fixed hub.

1. Mount the main shaft assembly vertically on asuitable stand. Position the stylus of the dialgauge on the gear. Zero the gauge. Lift up thegear and record the reading on the dial.

Gear end float

All dimensions in mm.

Note: The reverse gear is a sliding gear.

2. Remove the circlip retaining the 5th/6th speedsynchronizer hub.

3. Mount the puller over the 5th/6th speedsynchronizer hub and the 5th speed synchronizer

ring, taking care not to damage the teeth of thering. Pull off the hub, cone and ring.(On overdrive models, it may be necessary toengage the puller over the 6th speed gear also).Use tool N008.

4/13

F. Main shaft disassembly Disassembly

5thPinion (6th 4th 3rd 2nd 1st

overdrive)

Low limit 0.31 0.35 0.35 0.35 0.40High limit 0.53 0.48 0.48 0.48 0.57Range 0.22 0.13 0.13 0.13 0.17

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4/14

Main shaft assembly

Exploded view

Sequence N

1400-03011400-0303-00101400-0303-00201400-0303 00101400-0303-00301400-03051400-0307-00101400-0307-00201400-0307-00301400-0307-00401400-0307-0050

1400-0307 00601400-0309-00101400-0309-00201400-0309-00101400-0309-00301400-03111400-03131400-03191400-0321-00101400-0321-00201400-0321-00101400-03221400-0323-00101400-0323-00201400-0323-00301400-0323-00401400-0323-00501400-0323-00601400-0324

Description

Main shaft3rd speed gearSynchro flange3rd speed gear (B ratio)Loctite 648Needle roller bearingFixed hubSliding sleeveSynchro ringPlungerRoller

Synchro spring4th speed gearSynchro flange4th speed gear (B ratio)Loctite 648Needle roller bearing4th gear bearing sleeveCirclip 2.00 mm5th speed gearSynchro flangeOverdrive gearNeedle roller bearingFixed hubSliding sleeveSynchro ringPlungerRollerSynchro springCirclip 2.12 mm

1400-03261400-03281400-03411400-0342-00101400-0342-00201400-0342-00301400-03431400-0344-00101400-0344-00201400-0344-00301400-0344-0040

1400-0344-00501400-0344-00601400-03451400-03471400-03491400-0351-00201400-0351-00101400-03521400-03531400-03541400-03561400-03581400-03601400-036114101420

2430245524602465

Circlip 2.07 mmCirclip 2.02 mmNeedle roller bearing2nd speed gearSynchro flangeLoctite 648Needle roller bearingFixed hubSliding sleeveSynchro ringPlunger

RollerSynchro springCirclip 2.10 mmCirclip 2.05 mmCirclip 2.00 mmSynchro flange1st speed gearNeedle roller bearingReverse fixed hubCirclip 2.10 mm

Circlip 2.05 mmCirclip 2.00 mmNeedle roller bearingSpacerRoller bearing

Speedometer drive pinionCoupling flangeGrit shieldNyloc nut M33

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10. Carefully slide the 1st/2nd speedsynchronizer ring rearwards until the three rollersare clear of the groove in the sleeve. Remove therollers, sleeve and three plungers and springsfrom the synchronizer hub.

13. Clamp the shaft in the press, under the 3rdspeed gear.Note: It is vital that the 3rd speed gear issupported and that the flange on the shaft doesnot foul the supporting blocks or the bed of thepress when the shaft is being pushed through.Press or pull the shaft through the 3rd speed gear,3rd/4th speed synchronizer hub and 4th speedbearing sleeve. Use tool N008.

11. Remove the snap ring retaining the 1st/2ndspeed synchronizer hub.

12. Mount the puller on the 2nd speed gear andpull off the 2nd speed gear, 2nd speed

synchronizer ring and flange, 1st/2nd speedsynchronizer hub and bearing.

14. Dismantle the 3rd/4th speed synchronizerhub, as previously described in step 1.

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Note: The following parts must be heated at therecommended temperatures prior to assembly.Place the parts on a hotplate or in a temperature-controlled oven for at least 30 minutes to makesure they are thoroughly heated before placingthem in position. Once fitted and cooled, the partswill shrink to give an interference fit.

Sequence N

4th speed bearing sleeve 1400-0313Reverse fixed hub 1400-0353Reverse bearing inner race 1420Synchronizer hubs (3 off) 1400-0323-0010

1400-0307-00101400-0344-0010

Recommended temperature 85 C (180 F)

2. Support the main shaft, with the rear endfacing upwards. Fit the 2nd speed bearing.

1. Before installing the synchronizer assemblieson the main shaft, check the fit of eachsynchronizer ring to its synchronizer flange. Placethe synchronizer ring on its mating flange and,while holding the two parts firmly together,measure the clearance between the two ringsusing feeler gauges at several points around the

circumference, as shown. The clearance shouldbe between 0.5 and 1.9 mm. Replace both partsif the reading is not within the specified limits.Keep the synchronizer rings and flanges inrespective pairs for assembly in the same relativepositions.

The synchronizer flanges must be fitted to thegears using Loctite (see page 4/12-1).

The gearwheel and flange are then treated as asingle assembly.

3. Lubricate the bearing with clean oil and slidethe 2nd speed gear over the bearing.

4. Fit the 2nd speed gear/bearing assembly.Then fit the synchronizer ring.

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G. Main shaft reassembly

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5. Take the heated 1st/2nd speed synchronizerhub and place it over the splines on the mainshaft, ensuring that the wide slots in the hub alignwith the wide shoulders on the synchronizer ring.Allow to cool for 4/5 minutes, then use a softmetal hammer or a suitable mandrel to push thehub fully home.

7. Install the snap ring in the groove, taking carenot to damage the main shaft bearing surfaces.

6. From the range of graded-fit snap rings, selectthe thickest one that fits into the groove with theminimum of free play.

8. Check that the gear end float is within thetolerances stated in the chart.

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9. Install the three springs and plungers in thesynchronizer hub. Place the synchronizer sleeveover the hub and support it, with the internalannular groove just above the hub. Position thethree rollers as shown, resting on the heads of theplungers, and press downwards on the sleeve.This compresses the springs, allowing the sleeveto centralize in the neutral position.

11. Lubricate the 1st speed bearing and installthe steel cage bearing in the gear. Place thegear/bearing assembly on the shaft and in thesynchronizer ring.

12. Take the heated reverse gear fixed hub andslide it, boss facing upwards, over the splines onthe main shaft.

10. Install the 1st speed synchronizer ring on thesynchronizer hub. 13. Use a soft metal hammer or a suitableflanged mandrel to ensure that the hub is pushedfully home against the shoulder.

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19. Reverse the position of the shaft in a vice.Lubricate and install the 3rd speed bearing andthe 3rd speed gear.

21. Take the heated 3rd/4th speed synchronizerhub and slide it over the splines on the main shaft,ensuring that the wide slots in the hub align withthe wide shoulders on the synchronizer ring. Usea soft metal hammer or a suitable mandrel to pushthe hub fully home. Check again that theshoulders are in the correct slots.

20. Install the 3rd speed synchronizer ring overthe flange.

22. Check that the gear end float is within thetolerances stated in the chart.

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23. Install the three springs and plungers in thesynchronizer hub and install the synchronizersleeve and rollers as described in step 9.

25. Lubricate the 4th speed bearing and positionthe gear in the synchronizer ring and the bearingin the gear.

Note: If a smear of petroleum jelly is applied tothe outer edge of the bearing, this will support thebearing and it will stand proud of the gear andsimplify alignment of the bearing sleeve in thenext operation.

24. Install the 4th speed synchronizer ring on thesynchronizer hub.

26. Take the heated 4th speed bearing sleeveand place it inside the bearing and over the shaft.Use a soft metal hammer or a suitable flangedmandrel to ensure that the hub is pushed fullyhome against the synchronizer hub.

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27. Fit a new snap ring in the groove, taking careto not damage the main shaft bearing surface.

29. Lubricate the 5th speed bearing and installthe 5th speed bearing and gear on the shaft.

28. Check that the gear end float is within thetolerances stated in the chart.

30. Position the 5th speed synchronizer ring onthe 5th speed synchronizer flange.

Caution: Take care to use the correct flangewhen fitting the synchronizer flange to the 5thspeed gear. On overdrive models, it is possible to

fit the overdrive flange to the 5th speed gear.

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31. Take the heated 5th/6th speed synchronizerhub and slide it, boss facing downwards, over thesplines on the main shaft, ensuring that the wideslots in the hub align with the wide shoulders onthe synchronizer ring. Use a soft metal hammeror a suitable flanged mandrel, if necessary, topush the hub fully home against the shoulder.Check again that the shoulders are in the correctslots.

33. Install the circlip in the groove in the mainshaft.

34. Check the gear end float using feeler gauges.

32. From the range of graded-fit circlips, selectthe thickest one that fits into the groove with the

minimum of free play.

35. Install the three springs and plungers in thesynchronizer hub and install the synchronizer

sleeve and rollers as described in step 9.

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1. Place the selector assembly on the bench withthe selector block to the left. Mark the front of theshaft and the keys to aid reassembly.

3. Remove the selector forks from the shaft.

2. Hold the assembly by the selector block andwithdraw the interlock key from the rear.

4. Remove the cap screw from the selector blockand slide the block off the shaft.

Selector shaft assembly (vertical mounting version)

Note: The tapered cap screw is fitted onthe opposite side on horizontal mounting versions.

4/25

H. Selector shaft disassembly

Sequence N

1500-0401-00101500-0401-0020

1500-04031500-04051500-04071500-04091500-04091500-04111500-04131500-04151500-041717001710

Description

Selector blockPin

Reverse shift fork1st/2nd shift fork3rd/4th shift fork5th/6th shift forkOverdrive selectorSelector keyInterlock keySelector shaftSet screwOverdrive forkShift pad

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1. Place the selector key in the keyway on theselector shaft, with the three small bossestowards the front.

4. Support the selector shaft and slide in theinterlock key from the rear.

2. Put the selector block on the shaft and tightenthe cap screw at a torque of 35 to 39 Nm.

Note: If re-using the screw, apply Loctite 270 tothe screw-thread before fitting.

5. On overdrive models, the 5th/6th speed fork isreplaced by a selector. Check the fit of theselector before reassembling the gearbox.

3. Place the selector forks in their respectivepositions on the selector shaft.

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I. Selector shaft reassembly

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Note: Before reassembling the gearbox casing,ensure that each half-casing and the covers areperfectly clean and that all gaskets andjointing/sealing products are cleaned from themating faces. When re-using bolts coated withthread locking compound (Patchlock) or whenfitting cap screws in through holes, apply the

recommended thread locking product or sealant(Loctite 641).

3. Reverse the position of the casing and installthe outer cup of the layshaft front bearing in thecasing until it is approximately 5 mm below thefront face of the casing.

1. Support the front half-casing on woodenblocks. If removed, apply Loctite 518 sealant andinstall a new selector shaft core plug in the casing,from the inside, with the dished side facinginwards. Use a tube.

4. Mount the rear half-casing on the stand and, ifremoved, install new core plugs and rear busheson the selector shaft, as described in steps1 and 2.

2. Using the special tool, install the selector shaftbush in the casing. Drive in until fully home. Usea tube.

5. Reverse the position of the casing and, using

the special tool, install the outer cup of thelayshaft rear bearing in the casing until it is justbelow the rear face of the casing.Use tool N007.

J. Gearbox casing reassembly

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6. Place the spacer on the bearing cup, makingsure it is protruding above the rear face of thecasing.

9. Install the special locating sleeve over the mainshaft. Use tool N010.

7. Install the layshaft rear bearing cover on thecasing. Tighten the cap screws evenly at thecorrect torque, making sure that the bearing cup ispressed into the casing. Torque = 69 to 78 Nm.CAUTION: Take care to not obstruct thelubrication hole. Respect the orientation of thecover plate (see Fig. 22, page 4/7).

10. Position the selector shaft on the main shaft.Support the main shaft using the special tool anda hoist, and lower the assembly into the casing,making sure that the selector shaft enters into therear bush. Support the main shaft and theselectors approximately 20 mm above the finalinstallation position.

8. Install the main shaft rear bearing outer

cage/rollers assembly in the casing, with the snapring groove facing outwards. Temporarily installthe speedometer housing with two or three capscrews. Use a tube.

11. Lubricate and install the spigot bearing on the

main shaft. Fit the synchronizer ring and installthe input shaft assembly.

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12. Position the layshaft to mesh with the mainshaft.

15. Apply sealant to the rear half-casing matingflange and install the front half-casing. Fit the capscrews and nuts. Tighten at a torque of 51 to 58Nm.

13. Lower the hoist to allow the main shaft,layshaft and selector shaft to seat in theirrespective bearings and bushes. Remove thespecial tool. Ensure that the selector block ispositioned so that it does not foul the front half-casing.

16. On overdrive models, using a suitable probe(as illustrated), align the pivot pins with the holesin the casing. Apply sealant (Loctite 518) to thepivot pin flanges and insert the pins.

14. On overdrive models, install the fork pads inthe 5th/6th overdrive selector fork. Engage thefork and the pads in the synchronizer sleeve.

17. When aligning the right-hand pivot pin, lift upthe selector using a screwdriver through theremote control aperture. Tighten the cap screwsat the correct torque (20 to 40 Nm).

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18. Fit the spacer ring and the inner circlip on theinput shaft.

21. Select the thickest shim and place it againstthe layshaft bearing cup. Place the spacer on topof the shim.

Note: The spacer must stand proud of the frontface of the casing when the bearing cup is fullyseated against the bearing cone/rollers assembly.

Shims are available in the following thicknesses:

19. If removed, install a new oil seal in the frontcover of the input shaft bearing, using the specialtool. Press the seal firmly down to the shoulder,taking care to not damage the seal.Use a tube dia. 60.3 x 54.5 mm.

20. Lubricate the shaft seal surface and apply

flange sealant to the front cover mating face.Install the front cover and tighten the cap screwsat the correct torque (35 to 39 Nm).

4/30

Part N Thickness (mm)

F88891 0.051

F88892 0.127

F88893 0.254

F88894 0.508

Spacer 2.40

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23. Loosen the four cap screws as far as zerotorque loading, then retighten just sufficiently tonip the bearing cover plate. Using feeler gauges,measure the clearance between the cover and thecasing at several points. From the range ofgraded-fit spacers, select the thickest one that willgive the required preload on the layshaft bearings

from 0.075 to 0.125 mm for new bearings andfrom 0.00 to 0.05 mm for used bearings.

Example

Spacer thickness 2.40 mmadd shim + 0.508 mm

= 2.908 mmsubtract clearance - 0.30 mm

= 2.608 mmadd preload + 0.05 mm

= 2.658 mmsubtract spacer - 2.40 mm

= 0.258 mmShim required 0 254 mm

22. Install the layshaft front bearing cover(without sealant). Fit the cap screws withoutspring washers. Tighten the cap screws tightlyand evenly while rotating the input shaft forwardsthen backwards to settle the bearings. Continueto tighten the cap screws until some resistancecan be felt on the input shaft.

25. Turn the gearbox into the horizontal positionand remove the speedometer housing and thelocating sleeve from the main shaft.

26. Place the bearing thrust washer on the mainshaft, above the shoulder, against the rearbearing. Make sure that the oil groove is againstthe rollers.

4/31

24. Lubricate the layshaft bearing, install thegraded spacer of the selected thickness, applyflange sealant and install the cover plate. Applysealant and tighten the cap screws at the correcttorque (69 to 78 Nm).CAUTION: Take care to not obstruct thelubrication hole. Respect the orientation of thecover plate (see Fig. 24, page 4/7).

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27. Install the speedometer drive pinion ortachograph rotor on the main shaft, against thespacer.

29. Apply flange sealant and install thespeedometer housing. Note down the position ofthe longer cap screw. Tighten the cap screws atthe correct torque (35 to 39 Nm).

CAUTION: It may be necessary to install thespeedometer drive pinion prior to this stage.

28. If removed, install a new oil seal at the correctdepth in the speedometer housing, using thespecial tool. Press the seal firmly down to theshoulder, taking care to not damage the seal.Use tool N011.

30. Apply a light grease to the lips of the oil sealand install the drive flange. DO NOT hammer theflange onto the shaft as the bearing spacer maybe dislodged from its position on the shaft. Thiscould cause serious damage to the spacer,bearing or shaft and/or seriously affect the mainshaft end float.

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31. Fit and tighten the flange retaining locknut atthe correct torque, using a flange-holding wrench(490 to 588 Nm).

Reverse idler gear assembly

32. Install the tachometer sender unit or thespeedometer drive pinion and housing with a newsealing washer. Tighten at the correct torque (20to 27 Nm).

Sequence N

2600260326052610261526202625

Description

Reverse idler gear shaftO-ringReverse idler gearThrust washerNeedle bearingSpacerPin

33. Apply a thick coat of petroleum jelly to thereverse idler gear thrust washers and position

them in the gearbox casing.

34. Install the bearings and bearing spacer in thereverse idler gear and position the assembled

gear between the thrust washers and in mesh withthe layshaft and the main shaft reverse gear.

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35. Ensure that the thrust washer and the gearare correctly positioned and that the parallelgroove pin holes are correctly aligned and installthe reverse idler gear shaft with a new O-ring inthe casing. Take care not to dislodge thecomponents when the shaft is driven home usinga soft metal mallet.

Note: The pin hole in the idler gear shaft istapered.The larger diameter must be fitted towards theexterior of the gearbox.

37. Apply the specified sealant and install a newexpansion plug in the bore of the reverse idlershaft.

38. Install the reverse idler gear/PTO cover platewith a new gasket. Tighten the cap screws at thecorrect torque (35 to 39 Nm).

36. Align the pin holes and fit a new parallelgroove pin. Drive in until flush.

39. Turn the gearbox into the horizontal position.Rotate the selector block until the pin is in the

upwards position.

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40. Install the selector shaft detent plunger.Apply Loctite 242 sealant to give an efficient seal.

43. Apply sealant and install the reverse lampswitch. Tighten at the correct torque(16 to 22 Nm).

44. Check manually, using the gear change lever,that all the gears can be engaged. It may benecessary to rotate the input shaft in order to fullyengage the gears.

41. Apply a flange sealant and install the remotecontrol, making sure that the inner lever is locatedabove the selector block.

42. Tighten the cap screws at the correct torque(35 to 39 Nm).

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4/36

WARNINGRear casing closing plate (A) reassembly

(gearbox 4106 A) :

- correct assembly (1)- wrong assembly (2)

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5/1

Double Cone Synchronizers

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5/2

Mainshaft Disassembly

Note: All snap rings and circlips on the mainshaft are graded for selective fit. Take care not to score the

bearing surfaces of the mainshaft when removing or fitting the snap rings or circlips.

Note: The end float of the gears on the mainshaft is established in manufacture by machining the

components to fine tolerances. Before disassembly of the mainshaft the end floats should be checked

to ascertain whether they are within the recommended limits.

Where end float is found to be excessive it is necessary to check the gears, mainshaft, synchroniser

hubs and bearing sleeve for wear.

See Inspection of expendable parts and renew where necessary.

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5/3

Vrification des jeux de fonctionnement

Pignon FS 5me

FSO 6me

4me

3me

2me

1re

Minimum 0,31mm 0,35mm 0,35mm 0,35mm 0,40mm

Maximum 0,53mm 0,48mm 0,48mm 0,48mm 0,57mm

Tolrance 0,22mm 0,13mm 0,13mm 0,13mm 0,17mm

1. On peut vrifier le jeu defonctionnement de lensemble de larbreprincipal avec un comparateur cadran

ou des calibres dpaisseur lames.Monter larbre principal sur un supportconvenable. Placer le comparateur surle pignon et le mettre zro. Soulever lepignon et prendre note des mesures.

Dmontage

1. Monter larbre principal, ct lisse enhaut, dans un tau mordachestendres. Dposer lanneau conique(cne) du synchroniseur. Faire glissersoigneusement le manchon desynchroniseur de 5me/6me vitessesvers le haut jusqu ce que les troisrouleaux soient compltement dgagsde la rainure du manchon desynchroniseur. Dposer les troisrouleaux, le manchon de synchroniseur,

les trois plongeurs et les trois ressortsdu moyeu du synchroniseur.

End float check

Gear FS 5thFSO 6th

4th 3rd 2nd 1st

Minimum 0.31 mm 0.35 mm 0.35 mm 0.35 mm 0.40 mm

Maximum 0.53 mm 0.48 mm 0.48 mm 0.48 mm 0.57 mm

Tolerance 0.22 mm 0.13 mm 0.13 mm 0.13 mm 0.17 mm

End float may be checked with themainshaft assembled by using a dialgauge, as shown, or feeler gauges.

Mount the mainshaft assembly on asuitable stand. Locate the dial gauge onthe gear and zero the gauge. Raise thegear and record the reading.

Disassembly

Mount the mainshaft assembly, plainend uppermost, in a soft jawed vice.Remove the synchronizer ring.Carefully slide the 5th/6t synchronizersleeve upwards until the three rollersare clear of the groove in thesynchronizer sleeve. Remove the threerollers, the synchronizer sleeve, thethree plungers and three springs fromthe synchronizer hub.

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2. Dposer le circlip de retenue du moyeude synchroniseur de 5me et 6mevitesses.

3. Inverser larbre principal. Au moyendune presse ou dun extracteur

appropri, dposer la cage intrieure duroulement de larbre principal, le pignonde marche arrire et le roulement aiguilles du pignon de marche AR.

4. Dposer le circlip de retenue du moyeufixe du pignon de marche AR.

5. Au moyen dune presse ou dunextracteur appropri, enlever le moyeu

fixe du pignon de marche arrire et lepignon de 1re vitesse.

Invert the mainshaft assembly. Using apress or suitable puller remove the

mainshaft bearing inner, reverse gearand reverse gear needle roller bearing.

Remove the 5th/6th-gear synchronizerhub retaining circlip.

Remove the reverse gear fixed hubretaining snap ring.

Using a press or suitable pullerremove the reverse gear fixed hub

and 1st speed gear.

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6. Au moyen dune presse ou dunextracteur appropri, enlever le moyeufixe du pignon de marche arrire et lepignon de 1re vitesse.

7. Dposer le circlip de retenue dusynchroniseur.

8. Pour viter que les lments dusynchroniseur ne se sparent durant ladpose, monter loutil de retenue. Cetoutil se place dans larbre principal,bossage vers le bas, les trois pices deretenue situes sous le pignon de 2mevitesse. Rgler les pices de retenuesorte quil ny ait aucun jeu entre le

pignon de 2me vitesse et lensembledu synchroniseur

Nota: Si les divers lments dusynchroniseur se sparent, voir lasection approprie desinstructions de montage.

9. Au moyen dune presse ou dun outilappropri, dposer le synchroniseur etle pignon de 2me vitesse. Dposer le

roulement aiguilles.

Remove the 1st speed gear needleroller bearing.

Remove the synchronizer assemblyretaining circlip.

To prevent the synchronizer assemblyfrom separating during removal fit theretaining tool. The tool fits onto themainshaft, boss down, with the threeretainers located underneath 2ndspeed gear. Adjust the retainers so thatthere is no free play between 2ndspeed gear and synchronizer assembly

Note : Should the synchronizerseparate then refer to the relevantsection for assembly instructions.

Using a press or suitable tool removethe synchronizer assembly and 2ndspeed gear. Remove the needle roller

bearing

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10. Dposer soigneusement loutil deretenue et placer le synchroniseur et lepignon de 2me vitesse sur une surfacede travail convenable. Dposer lepignon de 2me vitesse.

11. Inverser larbre principal. Etant donnque le moyeu du synchroniseur de5me/6me vitesses nest passymtrique, identifier son orientation. Aumoyen dune presse ou dun extracteurappropri, dposer le moyeu dusynchroniseur de 5me/6me vitesses,le cne du synchroniseur et lensembledu pignon de 5me vitesse. Nota:Sassurer que les dents de la bride dusynchroniseur ne sont pasendommages.(Sur une bote de vitesses surmultiplie,

il peut tre ncessaire dengagergalement la presse ou extracteur sur lepignon)

12. Dposer le roulement aiguilles dupignon de 5me vitesse. (Sur les botesde vitesses surmultiplies, dposer la6me vitesse.)

13. Avec beaucoup de soin, dposer lecirclip de retenue du manchon deroulement du pignon de 4me.

Carefully remove the retaining tool andthen place the synchronizer assemblyand 2nd speed gear onto a suitable worksurface. Remove the 2nd speed gear.

Invert the mainshaft. As the 5th/6th-gear synchronizer hub is notsymmetrical, identify its orientation.Using a press, or suitable puller,remove the 5th/6th-gear synchronizerhub, synchronizer ring and 5th speedgear assembly. Note: Care must betaken to ensure that damage to theteeth on the synchronizer flange doesnot occur.(On an overdrive transmission it maybe necessary to engage thepress/puller also over the gear)

Remove the 5th gear needle rollerbearing. (On overdrive transmissionsthis will be 6th gear)

Carefully remove the 4th gear-bearing sleeve retaining snap ring.

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16. Dmanteler le synchroniseur de3me/4me de la manire dcrite auparagraphe 1.

17. Soulever et dgager le moyeu et le cne

de synchroniseur.

Dismantle the 3rd/4th-speed synchronizerassembly as previously described inparagraph one.

Lift off the synchronizer hub and

synchronizer ring.

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Mainshaft reassembly

Before assembling the synchronizer assemblies on to the mainshaft, check the fit of

each synchronizer ring to the relevant synchronizer flange.

Procedure for 3rd, 4th, 5th and 6th speed synchronisers.

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Placer le cne de synchroniseur sur la bridecorrespondante et, tout en gardant les deuxpices fermement ensemble, mesurer le jeuentre les deux pices au moyen de calibresdpaisseur lames en plusieurs endroits dela circonfrence (voir illustration). Le jeudevrait se situer entre 0,5 et 1,9 mm.Remplacer les deux pices si le jeu nentrepas dans les limites spcifies. Retenir les

cnes et brides des synchroniseurs parpaires apparis pour assemblage dans lesmmes positions relatives.

Procdure pour lessynchroniseurs de 1re et 2mevitesses

a) Placer lensemble du synchroniseur surune surface plate (lun ou lautre ctvers le haut)

b) Dposer la bride du synchroniseur.

c) Placer la bride du synchroniseur, pilotevers le haut, sur ltabli.

d) Dposer la cage intrieure du cne dusynchroniseur.

Place the synchronizer ring to the relevantflange and while holding the two parts firmlytogether, measure the clearance betweenthe two component parts using feelergauges at several points around thecircumference as shown. The clearanceshould be between 0.5 and 1.9 mm. Renewboth parts if the measurement is not withinthe specified limits. Retain the synchronizer

rings and flanges in their respective pairs forassembly in the same relative position.

Procedure for 1st and 2ndspeed synchronizers

Stand the synchronizer assembly on toa flat surface (Either way up).

Remove the synchronizer flange.

Place the synchronizer flange, spigotuppermost onto the bench.

Remove the synchronizer inner ring.

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e) Monter la cage intrieure du cne dusynchroniseur, languettes vers le haut,sur la bride du synchroniseur.

f) Dposer lanneau de frottement dusynchroniseur.

g) Poser lanneau de frottement dusynchroniseur sur la bride dusynchroniseur en sassurant que leslanguettes de lanneau de frottementsont positionnes dans les ranures de labride du synchroniseur.

h) Dposer le cne du synchroniseur.

Fit the synchronizer inner ring, tangsuppermost, on to the synchronizerflange.

Remove the synchronizer friction ring.

Fit the synchronizer friction ring on tothe synchronizer flange ensuring thatthe tabs on the synchronizer friction ringlocate into the slots on the synchronizerflange.

Remove the synchronizer ring.

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i) Monter le cne du synchroniseur sur lesynchroniseur.

j) Tout en tenant les pices fermement enmain, mesurer le jeu entre le cne et labride du synchroniseur au moyen duncalibre dpaisseur lames en diversendroits de la circonfrence (voirillustration). Le jeu devrait se situerentre 0,5 et 1,9 mm. Si le jeu mesurnentre pas dans les limites spcifies, ilfaut remplacer le synchroniseur.

k) Voir les paragraphes douze quinze dela procdure dassemblage dusynchroniseur de 1re/2me vitesses.

l) inverser le synchroniseur et rpter laprocdure.

Fit the synchronizer ring onto theassembly.

While holding the parts firmly together,measure the clearance between thesynchronizer ring and synchronizerflange using feeler gauges at severalpoints around the circumference asshown. The clearance should bebetween 0.5 and 1.9 mm. If themeasured dimension is outside thesetolerances then the synchronizerassembly must be changed.

Refer to paragraphs twelve to fifteen ofthe assembly procedure in the section1st/2nd speed synchronizer assembly.

Invert the synchronizer assembly andrepeat the process.

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Montage

Nota: Les brides dessynchroniseurs, part cellesposes sur les pignons de 1re et2me vitesses, doivent tre fixessur les pignons avec de la loctite.

1. Placer loutil de retenue, bossage enhaut, sur une surface approprie.

2. Placer le synchroniseur de 1re et 2mevitesses sur loutil de retenue, ensassurant que le chanfrein du manchondu synchroniseur est en haut.

3. Porter lensemble 85 Centigrade, puisplacer loutil de retenue et lesynchroniseur sur la table presse.

4. Monter le pignon de 2me vitesse sur lesynchroniseur en sassurant quecannelures du pignon sengagent dansles cannelures du synchroniseur.

Monter et lubrifier le roulement aiguilles.

Place the retaining tool, boss uppermost,on to a suitable surface.

Assembly

Note : The synchronizer flanges,apart from those fitted to the 1st and2nd speed gears, must be loctited tothe gears.

Place the 1st/2nd speed synchronizerassembly onto the retaining toolensuring that the chamfer on thesynchronizer sleeve is uppermost.

Heat the assembly to 85 Centigradeand then place the retaining tool andsynchronizer assembly onto the presstable.

Fit the 2nd speed gear to thesynchronizer assembly ensuring thatthe splines on the gear engage into thesplines on the synchronizer assembly.

Fit and lubricate the needle rollerbearing.

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7. Lubrifier et mettre en place le roulement aiguilles du pignon de 3me vitesse etle pignon de 3me.

8. Lubrifier la bride du synchroniseur dupignon de 3me vitesse puis monter lecne du synchroniseur.

9. Porter le moyeu du synchroniseur dupignon de 3me/4me vitesses 85C.Monter le moyeu du synchroniseur surles cannelures de larbre principal, ensassurant que les larges rainures sur lemoyeu du synchroniseur sont alignessur les larges paules du cne dusynchroniseur. Avec une presse,

pousser le synchroniseur en place fond.

10. Vrifier que le jeu de fonctionnement dupignon de 3me est situ dans leslimites de tolrance indiques dans letableau.

Lubricate and install the 3rd gearneedle roller bearing and 3rd gearassembly.

Lubricate the 3rd gear synchronizerflange and then fit the synchronizer ring.

Heat the 3rd/4th-gear synchronizer hubto 85 Centigrade. Fit the synchronizerhub over the splines on the mainshaftensuring that the large slots in thesynchronizer hub align with the largeshoulders on the synchronizer ring.Press the synchronizer fully home.

Check that the 3rd gear end float iswithin the tolerance stated in the chart.

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11. Assembler les trois ressorts etplongeurs dans le moyeu dusynchroniseur. Placer le manchon dusynchroniseur sur le moyeu dusynchroniseur et la soutenir au moyende la rainure intrieure qui se trouvejuste au dessus du moyeu dusynchroniseur. Positionner les trois

rouleaux comme le montre lillustration,reposant sur les ttes des plongeurs, etpousser fermement le manchon desynchroniseur vers le bas. Cette actioncomprime les ressorts et permet aumanchon du synchroniseur de secentraliser dans la position de pointmort.

12. Placer le cne du synchroniseur dupignon de 4me vitesse sur lesynchroniseur, en sassurant que lespaules du cne se positionnent dansles rainures du moyeu desynchroniseur. Lubrifier le cne.

13. Placer le cne du synchroniseur dupignon de 4me vitesse sur lesynchroniseur, en sassurant que lespaules du cne se positionnent dansles rainures du moyeu desynchroniseur. Lubrifier le cne.

14. Porter le manchon du roulement dupignon de 4me vitesse 85Centigrade et le positionner sur larbreprincipal et lintrieur du roulement aiguilles. Avec une presse, pousser lemanchon de roulement en place.

Assemble the three springs andplungers into the synchronizer hub.Place the synchronizer sleeve over thesynchronizer hub and support it withthe internal groove just above thesynchronizer hub. Position the threerollers as shown, resting on the headsof the plungers, and press downward

on the synchronizer sleeve. Thiscompress the springs allowing thesynchronizer sleeve to centralise in theneutral position.

Place the 4th gear synchronizer ringonto the synchronizer assemblyensuring that the shoulders on thesynchronizer ring locate into the slots ofthe synchronizer hub. Lubricate thesynchronizer ring.

Fit the 4th speed gear assembly.Lubricate the needle roller bearing andthen install it into the gear.

Heat the 4th speed gear-bearing sleeveto 85Centigrade and locate it onto themainshaft and inside the needle rollerbearing. Press the bearing sleeve intoposition.

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15. Monter un nouveau circlip dans larainure de larbre principal en prenantsoin de ne pas endommager la surfacede roulement de larbre principal.

16. Vrifier que le jeu de fonctionnement dupignon de 4me se situe dans leslimites de tolrance indiques sur letableau.

17. Monter le pignon de 5me vitesse.Lubrifier le roulement aiguilles puismonter dans le pignon.

18. Lubrifier la bride du synchroniseur dupignon de 5me vitesse. Monter le cnedu synchroniseur.

Fit a new snap ring into the mainshaftgroove taking care not to damage themainshaft-bearing surface.

Check that the 4th gear end float iswithin the tolerance stated in the chart.

Fit the 5th speed gear assembly.Lubricate the needle roller bearing andthen install it into the gear.

Lubricate the 5th gear synchronizerflange. Fit the synchronizer ring.

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27. Choisir, dans la gamme de circlipscalibrs, celui qui se monte dans larainure de larbre principal avec lemoindre jeu. Monter le circlip dans larainure, en prenant soin de ne pasendommager la surface de roulement aiguilles de larbre principal.

28. Vrifier que le pignon de 1re vitesse sesitue dans les limites de tolranceindiques sur le tableau.

29. Monter le roulement aiguilles dupignon de marche AR. Lubrifier leroulement, puis monter le pignon demarche AR, bossage en bas, sur larbreprincipal.

30. Porter la cage intrieure du roulementde larbre principal 85 Centigrade.Ensuite, le monter, paule vers le bas,sur larbre principal. Au moyen dunepresse, en cas de besoin, sassurer quele roulement est bien en place contrelpaule.

From the range of graded circlips selectthe one which fits into the mainshaftgroove with the least amount of freeplay. Fit the Circlip into the groovetaking care not to damage themainshaft needle roller bearing surface.

Check that the 1st speed gear is withinthe specified tolerance stated in thechart.

Fit the reverse gear needle rollerbearing. Lubricate the bearing and thenfit the reverse gear, boss down, ontothe mainshaft.

Heat the mainshaft bearing inner to 85Centigrade and then fit it, shoulderdown, onto the mainshaft. Use a press,if necessary, to ensure that the bearingis fully home against the shoulder.

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1st/2nd speed synchronizer assembly

Note : The synchronizer is supplied as an assembly. Parts that are used to make the complete

assembly are not available separately.

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Dmontage

1. Placer lensemble du synchroniseur surune surface plate, le pilote du manchondu synchroniseur vers le haut.

2. Pousser le manchon du synchroniseur

vers le bas.

3. Dposer la bride du synchroniseur.

4. Dposer la cage intrieure du cne dusynchroniseur.

Disassembly

Stand the synchronizer assembly on aflat surface with the spigot of thesynchronizer sleeve uppermost.

Push the synchronizer sleeve

downwards.

Remove the synchronizer flange.

Remove the synchronizer inner ring.

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5. Dposer lanneau de frottement dusynchroniseur.

6. Dposer le cne du synchroniseur.

7. Dposer les trois pices de retenue.

8. Prenant soin de ne pas garer les billesou les ressorts, soulever les poupes(plongeurs) de verrouillage pourrelcher les billes. Une fois les billesdposes, il est possible de dposer lespoupes de verrouillage et les ressorts.

9. Dposer le manchon du synchroniseur.

Remove the synchronizer friction ring.

Remove the synchronizer ring.

Remove the synchronizer sleeve.

Remove the three retainers.

Taking care not to lose the balls orsprings l i ft the detent poppets torelease the balls. Once the balls havebeen removed it is possible to removethe detent poppets and springs.

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10. Sils nont pas encore t dposs ladmarche huit, dposer les poupes etles ressorts de dtente.

11. Dposer le moyeu du synchroniseur.

12. Dposer le cne du synchroniseur(anneau conique).

13. Dposer lanneau de frottement dusynchroniseur.

14.Dposer la bague intrieure du cne dusynchroniseur.

If not already removed at step eightremove the detent poppets and springs.

Remove the synchronizer friction ring.

Remove the synchronizer inner ring.Remove the synchronizer hub.

Remove the synchronizer ring.

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Montage

1. Placer la bride du synchroniseur, pilotevers le haut, sur ltabli.

2. Monter la bague intrieure dusynchroniseur, les languettes vers lehaut, sur la bride du synchroniseur.

3. Lubrifier toutes les surfaces de lanneaude frottement du synchroniseur. Monterlanneau de frottement du synchroniseuren sassurant que les languettes sontpositionnes dans les rainures de labride de synchroniseur.

1

23

4. Monter le cne du synchroniseur en

sassurant que les zones dedgagement (1) sont alignes sur leslanguettes (2) de la bague intrieure dusynchroniseur et que les bossages (3)du cne du synchroniseur sont sur lagauche des languettes (2) de la bagueintrieure du synchroniseur (voirillustration).

Assembly

Place the synchronizer flange, spigotuppermost onto the bench.

Lubricate all surfaces of thesynchronizer friction ring. Fit thesynchronizer friction ring ensuring thatthe tabs locate in to the slots of thesynchronizer flange.

Fit the synchronizer inner ring, tangsuppermost, on to the synchronizerflange.

Fit the synchronizer ring ensuring thatthe undercuts (1) line up with the tabs(2) of the synchronizer inner ring andthat bosses (3) of the synchronizer ringare to the left hand side of tabs (2) ofthe synchronizer inner ring as shown.

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5. Les trous dans le moyeu du

synchroniseur placs en haut,

6. Monter le moyeu du synchroniseur ensassurant que les rainures troites sontalignes sur les bossages du cne dusynchroniseur.

7. Placer les trois pices de retenue dansles grandes cavits du moyeu dusynchroniseur, de telle sorte que lesjambes des blocs sengagent avec leslanguettes de la bague intrieure dusynchroniseur et les dgagements ducne du synchroniseur.

8. Prendre le manchon baladeur dusynchroniseur, ct tag vers le haut,et le monter sur le moyeu dusynchroniseur, en sassurant que lestrois bossages intrieurs du manchondu synchroniseur sengagent dans lesrainures du manchon.

With the holes in the synchronizer hubuppermost.

Place the three retainers in the largerecesses of the synchronizer hub sothat the legs of the blocks engage withthe tabs of the synchronizer inner ringand the undercuts of the synchronizerring.

Take the synchronizer sliding sleeve,stepped side uppermost, and fit it on tothe synchronizer hub ensuring that thethree internal bosses of thesynchronizer sleeve locate in the slotsof the synchronizer hub.

Fit the synchronizer hub ensuring thatthe narrow slots are in line with thebosses of the synchronizer ring.

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9. Mettre les poupes et les ressorts de 11. Placer la bille de verrouillage sur le

10. Placer la bille de verrouillage sur leressort, puis, au moyen dun outilappropri, pousser sur la bille deverrouillage pour comprimer le ressort.

12. Placer le cne du synchroniseur sur lemoyeu du synchroniseur de sorte queles trois bossages sengagent dans lestrois rainures troites sur le moyeu dusynchroniseur.

Place the detent poppets and springsinto the holes of the synchronizer hub.

Whilst the spring is compressed pushthe detent poppet downwards into thesynchronizer hub until the ball engageswith the annular groove of the sleeve.Fit the remaining detent springs, ballsand plungers into position.

Place the detent ball onto the springand then using a suitable tool pushagainst the detent ball to compress thespring.

Place the synchronizer ring on to thesynchronizer hub so that the threebosses engage with the three narrowslots on the synchronizer hub.

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13. Lubrifier toutes les surfaces de lanneaude frottement du synchroniseur. Poserlanneau de frottement dusynchroniseur, languettes en haut, surle moyeu du synchroniseur.

14. Poser la bague intrieure dusynchroniseur en position de sorte queles trois languettes soient alignes surles jambes des blocs.

15. Placer la bride du synchroniseur enposition de telle manire que sesrainures soient alignes sur leslanguettes de lanneau de frottement dusynchroniseur.

16. Tenir lensemble du synchroniseur versle bas, fermement contre ltabli, et,dans le mme temps, lever le manchondu synchroniseur vers le haut pourlengager en position neutre.

Lubricate all surfaces of thesynchronizer friction ring. Place thesynchronizer friction ring, tabsuppermost, on to the synchronizer hub.

Place the synchronizer flange in toposition ensuring that the slots of thesynchronizer flange align with the tabsof the synchronizer friction ring.

Hold the synchronizer assembly downagainst the bench and at the same timelift the synchronizer sleeve upwards toengage the neutral position.

Place the synchronizer inner ring in toposition ensuring that the three tabsalign with the legs of the blocks.

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1. Arbre principal.2. Roulement rouleaux aiguilles des

3me vitesse.3. Pignon de 3me vitesse.

4. Anneau conique (cne) desynchroniseur de 3me vitesse.

4a. Bride de synchroniseur de pignon de3me vitesse

5. Rouleau.6. Plongeur7. Ressort8. Moyeu de synchroniseur de

3me/4me vitesses9. Manchon de synchroniseur de

3me/4me vitesses10. Bride de synchroniseur de pignon de

4me vitesse

10a. Cne du synchroniseur de pignon de4me vitesse

11 Pignon de 4me vitesse12 Roulement aiguilles du pignon de

4me vitesse13. Manchon de pignon de 4me vitesse14. Circlip15. Roulement aiguilles du pignon de

5me vitesse (FS)Roulement aiguilles du pignon de

6me vitesse (FSO)16. Pignon de 5me vitesse (FS)

Pignon de 6me vitesse (FSO)17. Cne de synchroniseur de pignon de

5me vitesse (FS)Cne de synchroniseur de pignon de

6me vitesse (FSO)17a. Bride de synchronise ur de pignon de

5me vitesse (FS)Bride de synchroniseur de pignon de6me vitesse (FSO)

18. Rouleau19. Plongeur20. Ressort21. Moyeu de synchroniseur de pignon

de 5me/6me vitesses22. Bague de synchroniseur du pignon de

5me/6me vitesses23. Cne de synchroniseur du pignon de

6me vitesse (FS)Cne de synchroniseur du pignon de5me vitesse (FSO)

24. Circlip25. Roulement aiguilles du pignon de

6me vitesse (FS)Roulement aiguilles du pignon de5me vitesse (FSO)

26. Roulement aiguilles du pignon de2me vitesse

Mainshaft3rd gear needleroller bearing3rd speed gear

3rd gearsynchronizer ring3rd gearsynchronizer flangeRollerPlungerSpring3rd/4th speedsynchronizer hub3rd/4th speedsynchronizer sleeve4th gearsynchronizer flange

4th gearsynchronizer ring4th gear4th gear needle roller bearing4th gear sleeveSnap ring5th gear needle roller bearing (FS)6th gear needle roller bearing (FSO)

5th speed gear (FS)6th speed gear (FSO)5th gearsynchronizer ring (FS)6th gear

synchronizer ring (FSO)5th gearsynchronizer flange (FS)6th gearsynchronizer flange (FSO)RollerPlungerSpring5th/6th gearsynchronizer hub5th/6th gearsynchronizer sleeve6th gear

synchronizer ring (FS)5th gearsynchronizer ring (FSO)Circlip6th gear needleroller bearing (FS)5th gear needleroller bearing (FSO)2nd gear needle roller bearing

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27. Pignon de 2me vitesse28. Bride de synchroniseur29. Bague intrieure du synchroniseur30. Anneau de frottement du

synchroniseur31. Cne de synchroniseur32. Moyeu de synchroniseur de pignon

de 1re/2me vitesses33. Pice de retenue34. Ressort

35. Bille36. Poupe (plongeur) de verrouillage37. Manchon de synchroniseur de

1re/2me vitesses38. Circlip39. Pignon de 1re vitesse40. Roulement aiguilles du pignon de

1re vitesse41. Moyeu du pignon de marche AR42. Circlip43. Roulement aiguilles du pignon de

marche AR44. Pignon de marche AR

45. Roulement de larbre principal46. Tachygraphe47. Ecran cache-poussire48. Bride daccouplement49. Boulon

2nd gearSynchronizer flangeSynchronizer inner ringSynchronizerfriction ringSynchroniser ring1st/2nd gearSynchronizer hubRetainerSpring

BallDetent poppet1st/2nd speedSynchronizer sleeveCirclip1st speed gear1st gear needleroller bearingReverse gear hubSnap ringReverse gear needleroller bearingReverse gear

Mainshaft bearingTachographDust shieldCoupling flangeNut

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Tools

RENAULT TRUCKS divide tools into 3 categories :

General-purpose tools : Commercially available tools. 50 00 26 reference number (possibility of purchasing through the Renault

Trucks Spare Parts department). 4-figure reference number (tools with Renault Trucks reference number, but

available from the supplier).

Special tools : Specially created tools, distributed by the Renault Trucks spare partsdivision.

Locally manufactured tools : these tools are classified differently according totheir degree of sophistication :

4-figure reference number (represented by a drawing) : tools that are simpleto make without need for special qualification.

50 00 26 reference number (possibility of purchassing throughthe Renault Trucks Spare Parts department) : a certain skill is needed tomake these tools.

Three levels (or echelons) determine their assignment :

LEVEL 1 : Tools for servicing and minor tasks.

LEVEL 2 : Tools for major repairs.

LEVEL 3 : Tools for refurbishment.

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General-purpose tools

Tool ref. N Renault Trucks ref N Designation Level Qty Page

009 50 00 26 0821 Puller 2 1 4/15

008 50 00 26 0827 Puller 2 1 4/13

001 50 00 26 0832 Puller 2 1 3/4

005 50 00 26 0843 Puller 2 1 4/3

002 50 00 26 1000 Universal stand 2 1 4/3

Special or specific tools

Tool ref. N Renault Trucks ref N Designation Level Qty Page

010 50 00 26 3295 Guide 2 1 4/28

003 50 00 26 3296 Fitting 2 2 4/3

004 50 00 26 9134 Holding wrench 3 1 4/3

Locally manufactured tools

Tool ref. N Renault Trucks ref N Designation Level Qty Page

006 3292 Hook 2 1 4/6

007 3293 Pusher 3 1 4/7

011 3294 Pusher 1 1 4/32