Here - Land Rover Series One Club
Contents
1. Copyright by Ulrico Becker 16 274 edition OVERDRIVE b 1 MANUAL References of bearings and seals ree o e oa Reference 1 1 RTC7173 G 50x58x4 Oil seal Input shaft j Standard item easily sourced G sits inside the output refers to a standard type seal shaft 2 1 RTC7173 75x95x13 B2 Oil seal output shaft Easily sourced B2 refers to a seal Needle roller bearing Standard item easily sourced K refers to a simple needle roller bearing 4 1 RTC7188 30x35x17 Needle roller bearing Standard item easily sourced refers to a simple needle roller bearing 5 4 RTC7175 30x36x25 Needle roller bearing Specific part for overdrives The dimension is very rare and should be sourced va one of the Land Rover sources Alternatively a search via a specialist dealer may prove helpful RTC7193 One of the original references is NLA but this doesn t matter as they differ only in the length of the distance sleeve Alternatively a bearing K 30x36x20 can be used but it is recommended to then shorten the distance sleeves and use two wherever one of K 30x36x25 would be used Dont use 3 together with two distance sleeves as the middle bearing will not be really loaded e 1 10379 6308 Ball bearing Standard item 1 4 RTC7184 3047 Needle roller thrust Standard item The LR reference bearing includes a set of hardened races 8 AS 3047 Hardened race 2 RTC7186 2035 Needle r2. 2 9 edition SERIES OVERDRIVE 7 vehicles MANUAL Assembly to the vehicle 1 Filthe unit with 0 4 litres of EP90 2 the output gear shaft to allow the oil to reach all areas Use a special grease to lubricate the rectangular splines inside the main shaft This grease should maintain a constant viscosity over a large temperature range MoS or something similar will do a good job Bearing suppliers stock a range of suitable greases 4 assemble the overdrive unit back to the vehicle unless you have a comfortable way to reach it from underneath the safest way is as follows a Place the unit on some sort of support box reversed bucket jack etc and push it under the vehicle roughly to the position where it is fitted and oriented in the way it will be inserted b From above after lifting the seat box lid take a rope or sling and sling it once around the output gear shaft c Coming from the right side of the vehicle lift the unit with your left hand and pull the sling up with your right hand The unit can thus be easily presented to the gearbox Laying under the vehicle trying to lift it with both hands requires some strength and only gives bad leverage The risk of letting the unit fall onto whatever or whoever is underneath it must not be disregarded 5 Slide the unit into the gearbox It should go in nearly all the way but sometimes getting it into mesh does not work at first trial
3. REPAIR AND SERVICE MANUAL FOR FAIRE Y SUPERWINCH OVERDRIVES FOR LAND ROVER SERIES VEHICLES To service products that were sold by Copyright by Ulrico Becker vehicles MANUAL 275 Contents arm a o oc oU Q9 NM A o 14 15 Overview Schematic drawing and references Parts description Schematic operations of an overdrive unit Disassembly Preparation for removal of the main components Removal of the main shaft Removal of output gear shaft lay gear and lay shaft Disassembly inspection and assembly of the synchro hub Inspection of components References of bearings and seals Some sources for spare parts Pre assembly of housing laygear main shaft and output gear shaft before final assembly Final assembly Assembly to the vehicle Copyright by Ulrico Becker als edition OVERDRIVE wf SERIES MANUAL Z3 PP vehicles Overview B This manual covers disassembly inspection and assembly operations for Fairey Overdrive Units to fit Land Rover Series III vehicles Fairey OD units were later manufactured by Superwinch following the same design Today overdrives are sold and manufactured by RoversDownSouth E It does not cover the clutch sleeve unit B References given for bearings and seals are according to international standard and should allow the user to source them at any bearing or industrial supply dealer B No speci
4. Ulrico Becker 13 274 edition OVERDRIVE fie SERIES MANUAL 92 53 ROVER vehicles Disassembly inspection and assembly of the synchro hub 6 Noinformation could be obtained on the nominal free length of the springs 503805 fig 2 If they were not broken or twisted the author has used them again When assembled they should firmly hold the outer hub in a neutral position Their reason for being is to prevent the hub from wandering and wearing down the swivel pads The hub could then inadvertently crash into input gear or output gearshaft The assembly of the springs sliding blocks and balls is less complicated than one would expect Take only one set and wedge the spring in between inner and outer hub as shown Then place the ball onto the spring and press it with your thumb nail in its position under the outer hub Alternatively a fine blade can be used To repeat it for the next set move the inner hub out as far as possible without releasing the set assembled previously and tilt it Even if this can be done only by a small amount it will be sufficient to allow assembly of the second set in the manner described above The third set obviously requires more force to press the ball under the outer hub because the amount of tilt is now very much reduced with two sets already in place It is strongly recommended to do this in a protected environment large card board box or room where everything can be found aga
5. of timber underneath to soften its fall b cm only 6 Liftthe overdrive unit to free the mainshaft Be careful not to hit the synchro hub assembly If this falls out it may spring apart and the three balls and springs between inner and outer hub may get lost The main shaft disassembly is now completed Copyright by Ulrico Becker 9 edition OVERDRIVE SERIES MANUAL SZ vehicles Removal of output gear shaft lay gear and lay shaft Removal of output gear shaft 1 Place the overdrive unit in a vertical position again Remove the inner race of the needle bearing and the axial thrust washer both belong to RTC7185 fig 2 After removal of the main shaft they will be laying loose on top of the synchro hub Carefully remove the synchro hub assembly 561392 fig 2 through the top cover opening Avoid actuating the hub as this may let the springs and balls jump out Should this however happen the world will still continue to turn Assembly and disassembly of this group will be treated later The laygear RTC7192 fig 2 needs to be moved out of its position to allow withdrawal of the output gearshaft RTC7176 fig 3 Pull the layshaft RTC7194 fig 2 out of the housing and push the laygear away from the output gearshaft deeper into the housing If not yet done so remove the second synchromesh cone 571936 fig 2 The output gearshaft will now slide out easily Inside t
6. room for the ball to be pushed out of the recess in the selector shaft when changing gears If after assembly of the unit to the vehicle changing overdrive gears appears to be too stiff the bottom grub screw can be turned out a little bit to reduce pressure on the ball 26 Place the selector shaft in the neutral position engaging the ball in the middle position 27 Fitthe pinch bolt 255227 fig 1 This will only go in if the selector shaft is correctly positioned and turned in a way that the slot in the middle will be in line with the bolt hole in the selector fork Attention Make sure the synchro hub is exactly in the middle between the two synchro cones before tightening the pinch bolt The slot in the selector shaft allows for some variation in posi tioning the fork If this is not done properly the gear towards which the synchro hub has the longer travel may jump out Check equal travel and central position in neutral after tightening the pinch bolt The more the swivel pads 532943 fig 2 are worn the more this becomes important 28 Fit the sealing plate for the selector shaft together with a new o ring RTC7167 fig 1 29 Try the gears out and check that everything works the way it should by moving the selector fork into the different positions 30 Puta new seal to the cover plate RTC7182 fig 2 silicone serves well or cut one from cork or paper and fit it to the housing Copyright by Ulrico Becker 30
7. 7165 O ring service kit comprising 4 items 1 7166 Sealing plate for selector shaft RTC7167 Screw M5 x 10 mm Securing sealing 2 59105101 Spring washer M5 plate to casing 2 WL105001 Selector fork 522003 Swivel pads for selector fork 2 532943 Pinch bolt fork to shaft 5 16 UNF x 7 8 1 255227 Oil seal service kit comprising 2 items 1 7173 Thrust bearing service kit RTC7174 Needle bearing service kit 1 17 7175 Output gearshaft 1 RTC7176 Drain plug 1 RTC7177 Washer for drain plug or dipstick 2 RTC7178 Roller bearing RTC7179 Gasket overdrive to transfer box 1 622047 Dipstick 1 RTC7180 Detent service kit RTC7181 Stud rear cover to main casing 4 7191 Mainshaft 1 7168 Lockwasher securing clutch sleeve 1 7169 Clutch sleeve RTC7170 Needle bearing service kit RTC7171 Circlip service kit comprising 5 items 1 7172 Ball bearing 1 103790 Circlip service kit comprising 5 items 1 7172 Needle bearing service kit 1 RTC7188 Shim pack comprising 8 assorted shims for laygear and mainshaft A R RTC7189 Thrust bearing service kit 2 RTC7186 Collar 1 RTC7190 O ring service kit RTC7166 Spring washer M8 Rear cover to 4 WM103001 Nut main casing 4 GHF213 Gasket for top cover plate RTC7182 Top cover plate 1 7183 Plain washer 8 4 WD108051 Screw M8 x 16 mm 4 5 108161 Thrust bearing service kit 3 RTC7184 Synchromesh cone 2 571936 Inner and outer synchro
8. ERDRIVE 2 a vehicles MANUAL 255227 522003 y 532943 2 5 105101 2 d BH108101 2 NH108041L 2 WL105001 2 E RTC7166 2 i Lmcna 534907 3 RTC7196 3958 609 RTC7197 RTC7161 RTC7162 figure 1 65205 NSS RTC7197 RTC7189 QAY menz RTC7180 RTC7172 RTC7188 P NSS 1D3790 RTC7187 RTC7179 XS SH108161 4 b dn RTC7173 WD108051 4 RTC7183 RTC7176 RTC7178 2 RTC7177 ie RTC7194 503805 3 NN e RTC7182 RTC7192 d RTC7189 5 RTC7184 RTC7173 E ENV RTCZ175 Oy 3 es p Ea i Nor figure 2 figure 3 Copyright by Ulrico Becker wies edition OVERDRIVE 2 SERIES MANUAL vehicles Description Qty Part No Knob for operating lever 1 RTC7158 Locknut M12 2 112041 Operating lever RTC7159 Shakeproof washer M12 1 WF112001 Pivot kit 1 7160 Sealing plate Transmission 1 7196 Rubber grommet tunnel 1 7195 Self tapping screws 3 534907 Split pin 1 16 x 1 2 2 3958 Plain washer 1 4 2 RTC609 Link rod 1 7161 Clevis pivot to link rod 1 RTC7162 Clevis pin link rod to selector shaft RTC7163 Insulator for clevis pins 2 RTC7197 Bracket supporting pivot 1 7164 Spring washer 8 Securing 2 WM108001 Nut M8 bracket to 2 GHF213 Bolt M8 x 50 mm gearbox 2 BH108101 Selector shaft 1 RTC
9. There are two options to achieve this pull the unit out again until you can turn the output gear shaft by hand Turn it a little bit and try again Alternatively jack the vehicle up at the rear and turn the gears moving the hand brake drum The main gearbox must be in neutral The overdrive can be pushed in over the last 10 mm by tightening the six nuts Note that two of the nuts can only be started before the unit is right in Do not forget to fit the clip for the speedo cable under one of the two top nuts sometimes the teeth of the main shaft do not slide over the corresponding teeth of the drive dog and prevent the unit to be pushed in the last 10mm In these cases put the transferbox into neutral and the gearbox in third or fourth gear Crank the engine with the starter motor for one or two seconds and try again Repeat this procedure until the overdrive slides in or can be pulled in by tightening the nuts 6 Tighten the nuts and reconnect the lever linkage Copyright by Ulrico Becker 91 274 edition
10. al tooling is required apart from circlip pliers for external circlips A vernier caliper and a pen to mark metallic surfaces can prove useful Access to a press is helpful but not vital if a large vice is available A dentist s mirror and a small torch light may also prove useful B This manual has been compiled with utmost care However it is not an official manual but has been written out of personal interest with the rebuilding of Land Rover Series vehicles The author is a mechanical engineer who has been involved in the automotive industry for many years B All explanations given have been verified on the author s overdrive units and intended to give a guide line to an easy rebuild of the unit Typing mistakes have been eliminated where found However no responsibility for any problems encountered during operations can be the liability of the author The manual is intended as a guide line only and requires some knowledge by any user to properly execute the rebuild B Many thanks to Moci who with his six years of age proved himself to be a reliable partner in holding components for taking pictures and an unerring hunter when looking for springs that had jumped And to John Denham in correcting my english and giving a lot of advice regarding technical precision and clarity and Rik Thiel who provided the schematic drawing on overdrive operation modes Both live in Australia Copyright by Ulrico Becker 2 274 edition SERIES OV
11. e for the seals lip The author has been informed that some OD units have a slight groove machined on the inside of the output gear shaft to locate the seal This unit here however did not show this groove 2 Lubricate the inside of the output gear shaft to allow the seal to slide easily into its position Grease the lip of the seal to avoid it running dry when putting the unit back into operation Present the seal to the output gear shaft and push it in with your hand Turn it into horizontal position 3 Use the main shaft as a ram and push the seal into the output gear shaft until the mark is level with it s top or the seal settles inside the groove Copyright by Ulrico Becker 19 2 9 edition OVERDRIVE wf SERIES MANUAL 9 vehicles Pre assembly of housing laygear main shaft and output gear shaft before final assembly 4 Slide the bearing race and the bearing RTC71 74 fig 3 onto the main shaft and lubricate it with EP 90 5 care to place the lower race the thicker one in its correct position It is chamfered on one side and this chamfer needs to face towards the input end of the main shaft 6 Slide the two radial bearings and the distance sleeve RTC7175 fig 3 over the main shaft and lubricate the bearings with EP 90 Place the main shaft on a round support of at least 50 mm height and smaller in diameter than the main shaft This is needed to allow the o
12. e meshed strainer to retain any metallic components for analysis Preparation for disassembly of the main components 1 Wash and clean the unit from the outside to avoid mud and particles to contaminate your working surface Remove the top cover plate RTC71983 fig 2 Remove the detent grub screws RTC7181 fig 1 starting with the one on the top side This serves to limit maximum travel of the selector shaft Care needs to be taken with the one on the bottom side It compresses the selector spring to press a ball onto the selector shaft This fits into three recesses on the shaft marking the positions low neutral and high Copyright by Ulrico Becker 6 edition OVERDRIVE 55 SERIES MANUAL gy WAP vehicles Remove the sealing plate for the selector shaft RTC7167 fig 1 Hemove the pinch bolt 255227 fig 1 Pull the selector shaft out of the housing and carefully remove the selector fork 522003 fig 1 together with the swivel pads 532943 fig 1 Should they fall into the housing during the procedure retrieve them once the main and lay shaft have been removed Remove the rear cover plate It is recommended to have the unit in a vertical position for the next operations Place it on the bench resting on the output gearshaft and support it by suitably sized pieces of timber Copyright by Ulrico Becker edition Removal of the main shaft Removal of t
13. e protrudes a little bit from the main shaft This is normal and no reason for concern Slide the needle bearing part of RTC7185 fig 2 over the inner Fit the axial needle roller bearing RTC7186 fig 2 Fit the second synchromesh cone The roller bearing ID3790 fig 2 is best fitted onto the input gear RTC7187 fig 2 using a press Alternatively it can be done in a vice Copyright by Ulrico Becker 2 274 edition SERIES OVERDRIVE 2 5 X 1 Ca vehicles MANUAL Final assembly 15 Fitthe large circlip RTC7172 fig 2 to secure the roller bearing Slide the input gear assembly over the main shaft and press it into the housing As it is a loose fit it will slide in easily No problems should be encountered bringing it into mesh with the laygear Insert the first distance sleeve then the radial needle roller bearing and last the second distance sleeve all RTC7188 fig 2 Copyright by Ulrico Becker 28 274 edition Final assembly Copyright by Ulrico Becker edition POVER Fit the shims 7189 fig 2 and then the second axial bearing group RTC7186 fig 2 The shims control the end float of the main shaft This is only measurable once the rear cover has been bolted to the housing It can be checked by rocking the output gearshaft forwards and backwards The output gearshaft is held on the mainshaft via the i
14. he main shaft Remove circlip and collar RTC7172 and 7190 fig 2 Hemove the next circlip then the axial bearing group RTC7186 fig 2 consisting of two hardened races and the bearing cage and finally the pack of shims RTC7189 fig 2 These serve to adjust the end float of the whole main outputshaft assembly 3 Remove the input gear assembly RTC7187 fig 2 together with the ball bearing ID3790 fig 2 It should come out easily as it is designed to be a loose fit Should problems be experienced however warming the housing with a blow torch will normally free it If no such tool at hand leave it in until the output gear shaft has been taken out then tap it out from inside the housing Take care not to lose the needle bearing and the two distance sleeves inside RTC7188 fig 2 Copyright by Ulrico Becker 8 2 9 edition SERIES OVERDRIVE 2 x x vehicles MANUAL Removal of the main shaft Hemove the second axial needle bearing group and the radial needle bearing RTC 7186 and RTC7185 fig 2 Take the synchromesh cone out 571936 fig 2 The inner race RTC7185 fig 2 is a light press fit on the mainshaft and holds the mainshaft in its position inside the output gear shaft 5 With a soft mallet tap the mainshaft forward until the inner race is freed As the main shaft will drop free it is important to have the OD unit in vertical position and place a piece
15. he output gearshaft is an oil seal part of RTC7173 fig 3 that runs on the main shaft Remove this by pushing it down on one side It will pivot and can then be easily pulled out Copyright by Ulrico Becker 10 edition me SERIES aie vehicles Removal of output gear shaft lay gear and lay shaft Hemove the laygear the axial and radial needle bearings and the shims to control the end float RTC7189 RTC7184 RTC7193 and RTC7192 all fig 2 Tap the oil seal between output gear shaft and housing part of RTC71783 fig 3 and the roller bearing RTC7179 fig 3 out using a suitable drift Carefully tap the bearing only This will then also push the seal out The disassembly of the unit is now completed Copyright by Ulrico Becker 41 edition gt ROVER Disassembly inspection and assembly of the synchro hub The unit can be easily separated by just pushing the inner or outer hub beyond the holding point of the balls Just hold it with both hands and push the inner hub out with your thumbs It is best done inside a cardboard box covered with a towel to avoid springs and balls to fly away Wash all components The teeth of the outer hub show marks similar to wear marks They are ma chined on purpose to prevent the gears from jumping out when under load The splines of the inner hub did not show any marks on the unit assembled here It is unlikely for there to be st
16. he tool used to prevent movement of the laygear bearings out and move the laygear to be in mesh with the output shaft gears Centre the bearings with a screw driver or piece of round tubing 5 Fit anew O ring RTC7166 fig 2 to the lay shaft 6 Insert the lay shaft and drive it home This will probably require some two or three attempts before the shims and bearings are well centred Do not apply force as very thin shims may get bent when pushed into the bore 7 Fit the thrust washer part of RTC7185 fig 2 Copyright by Ulrico Becker 25 274 edition SERIES OVERDRIVE 2 N vehicles MANUAL Final assembly 8 Lubricate the inner surface of the inner own C bearing race part of RTC7185 fig 2 us 5 x yes Le ROS P pe H3 9 Slide it over the main shaft 10 Use a suitable drift in this case a piece of tubing to drive the race home It is a light press fit and holds the synchro hub in place on the main shaft One of the axial bearing races has been used to bridge the gap in diameter between tubing and inner race It is important for the output gear shaft to be resting only on the axial bearings on the main shaft Make sure this is the case and the output gear shaft is not being supported by anything else Copyright by Ulrico Becker 26 274 edition SERIES OVERDRIVE gt vehicles MANUAL Final assembly For reasons not known the inner bearing rac
17. hub 1 561392 Spring 3 503805 Ball 3 52459 Sliding block 3 553084 Needle bearing service kit 1 RTC7185 Input gear assembly 1 RTC7187 Needle bearing service kit 1 RTC7193 Laygear 1 RTC7192 Lavshaft 1 RTC7194 Copyright by Ulrico Becker 4 edition SERIES OVERDRIVE A be vehicles MANUAL ochematic operations of an overdrive unit am t Se n EUER EP Mainshaft Output gearshaft_ HN q an Laygear NE Inputgear Synchro hub B In position out the synchro hub is in its forward position and couples the blue mainshaft directly to the orange output gearshaft The laygear idles B In position the synchro hub is in its rear position and couples the blue mainshaft to the green input gear Torque is then transmitted via the olive laygear to the orange output gearshaft Picture compiled by Rik Thiel Copyright by Ulrico Becker 5 274 edition SERIES F vehicles Preparation for removal of main components Removal from the vehicle 1 Disconnect the link rod RTC7161 fig 1 from the selector shaft Remove the six nuts holding the OD in place and pull it out of the gearbox Two nuts can only be completely removed once the unit is pulled back by about 10mm Drain the oil by removing the drain plug RTC7177 fig The unit contains 0 4 of EP90 type oll It is advisable to drain the oil through a fin
18. in If you have one but a i who has one because the springs fly b um amp yp a pa EEE far when they fly Copyright by Ulrico Becker 14 edition OVERDRIVE aff SERIES MANUAL Q3 vehicles Inspection of components B Inspection of components should be done taking into account the possibility of replacing worn or damaged parts Gear boxes can still have a long life in them even if gears and other parts are quite worn BH Components with chipped teeth should be replaced Even if the tooth isn t completely gone yet this is an indicator to a problem that will only become worse if not cured B Gears with signs of pitting may still make many miles but will be noisy B If the effort has been spent to dismantle an overdrive unit and the history of this unit is unknown all bearings and seals should be replaced B f seals have left a groove on the shaft go with housing and shaft to a specialist dealer and look for either a seal with a different position of the lip or for shims that will move the seal s lip onto another part of the shaft Speedy sleeves may also be an option B The races for axial needle roller bearings components starting with AS in the table on page 17 have to be replaced if any signs of wear apart from shiny surfaces can be noticed B Bearing surfaces with signs of wear should be replaced Needle bearings will not last long if running on pitted or otherwi
19. nner racing part of RTC7185 fig 2 and shows no end float The main shaft requires a definite end float Its amount however is not critical as long as it is clearly identifiable The unit shown has an end float of around 1 5 mm Rovers Down South say that all end floats in the unit should be between 0 05 and 0 1 mm None of the authors units however has ever shown such a small value Fit the first circlip part of RTC7172 fig 2 Note that the two circlips are of dif ferent thickness They must not be inter changed as the thicker one has to with stand the unit s axial operating loads Fit the collar RTC7190 fig 2 and the second circlip 290 SERIES OVERDRIVE S vehicles MANUAL Final assembly 21 Fit the o ring RTC7166 fig 2 onto the cover and bolt the cover onto the housing Check that end float is noticeable 22 Slide the selector fork 522003 fig 1 with swivel pads in place onto the grove in the synchro hub Take care not to loose the swivel pads as retrieval at this stage is more difficult 23 Fit a new o ring to the selector shaft 24 Slide the selector shaft RTC7165 fig 1 through housing and selector fork The milled flat surface needs to point upwards 25 Fit the grub screw RTC7181 fig 1 with the little pin from the top and the ball spring and smaller grub screw from the bottom Fully tighten the smaller one and then turn back 2 3 turns This will allow for sufficient
20. oller thrust Standard item The LR reference bearing includes a set of hardened races AS 2035 Hardened race meme Eu 0000 layshaft plate selector shaft shaft cover RTC7179 75 25 Needle Roller Bearing Standard item SERIES vehicles Copyright by Ulrico Becker 1 edition SERIES OVERDRIVE 2 F vehicles MANUAL Some sources for spare parts B LEGS Shropshire UK B Rovers Down South New Orleans USA B PG Winches Cornwall UK B John Craddock Derbyshire UK There may of course be some more like the specialist gear manufacturers or the companies that produce synchromesh cones for the automotive industry Above addresses however should provide some first assistance when looking for replacement parts The whole range only seems available from Rovers Down South It is understood that they have bought the rights of Superwinch for these products During the rebuild of the unit shown they have been very helpful Copyright by Ulrico Becker 18 274 edition OVERDRIVE fim SERIES MANUAL lt vehicles Pre assembly of housing laygear mainshaft and output gearshaft before final assembly 1 mainshaft is an ideal tool to position the oil seal inside the output gear shaft Mark it at about 70 mm from the input end High precision is not required for positioning of the oil seal Basically all of the shiny circumference can serve as a running surfac
21. rong wear marks on the splines of the bore and the corresponding splines on the main shaft If there are some play can be tolerated Too much play may affect the gear selection The teeth should be sharp and only a little rounded The unit shown here shows some wear but will still work well for many miles Their function is to guide the outer hub when gliding over the synchromesh cone onto the teeth of output shaft or input gear If the teeth are well rounded gear selection will be more difficult It is best to replace the hub then The same criteria are valid for the teeth of the synchromesh cones and the teeth on the output gearshaft Copyright by Ulrico Becker 12 274 edition OVERDRIVE fe SERIES MANUAL a V vehicles Disassembly inspection and assembly of the synchro hub 4 Ifall components are found satisfactory prepare assembly It is advised to assemble inner and outer hub in a similar radial position against each other as they were found in These three possible positions are defined by the marks left by the balls Place inner and outer hub into each other and verify that the parts can slide easily against each other Both parts should be oily when doing this to avoid binding This could happen if they are completely dry although there is no problem Mark the selected position 5 sliding blocks 553084 fig 2 are not symmetrical The curved side has to show outwards Copyright by
22. se damaged surfaces If this surface is on a costly component like the output gear shaft the whole shaft should be replaced Alternatively on bores and shafts a machine shop can shrink a hardened bush into or onto these components which is then ground to size and surface requirements This is however only viable for people with a close contact to such a facility Otherwise this can be more expensive than replacing the part Synchromesh cones 571936 fig 2 show an array of elevated lines on the inside These serve to build oil pockets which help preventing the brass cone to stick on the steel cone on gears or shafts and maintain controlled friction conditions which are essential for smooth gear changes If these lines are worn to the degree of nearly having disappeared the cone has to be replaced B The swivel pads 532943 fig 1 should present an even wear pattern and show no strongly asymmetrical shape If they have too much play in the fork 522003 fig 1 it is advisable to replace them Copyright by Ulrico Becker 15 274 edition SERIES OVERDRIVE 59 F vehicles MANUAL References of bearings and seals Apart from one all bearings and seals conform to common industrial standards and are available via specialist dealers or industrial supply companies The table given below is a compilation of all bearings and seals but the needle bearing of the clutch sleeve This is to assist local sourcing of these components
23. the bearings Slide the bearing packages RTC7184 fig 2 in as shown starting with the bottom one The shims RTC7189 fig 2 coming out from disassembly should be used again Their purpose is to limit the end float of the lay gear and they have been selected according to interference of laygear and housing tolerances Bearings and races are standardized and replacements will be fully interchangeable In the unit shown shims were found at the front end of the lay gear and will be inserted there again Put a drift chisel or comparable tool into the lay gear bore to avoid shims bearings and races to move beyond the bore diameter Move bearings races and shims to the inside away from the gears teeth Mainshaft output gearshaft assembly and housing are now ready to be joined Copyright by Ulrico Becker 23 274 edition OVERDRIVE 23 gt SERIES MANUAL lt lt vehicles Final assembly 1 Select two suitable supports for the housing which will keep it roughly in its definite position after being joined with the shaft assembly 2 Carefully slide the housing over the mainshaft output gearshaft assembly until it rests on the supports Copyright by Ulrico Becker 24 274 edition BOER Final assembly 3 Carefully present the synchro hub assembly to the shaft assembly making sure the broad flat shoulder is pointing towards the output gearshaft 4 t
24. utput gearshaft to be placed on the mainshaft Copyright by Ulrico Becker 20 274 edition SERIES vehicles output gear shaft before final assembly 7 Slide the output gearshaft over the main shaft Take care not to damage the seal inside the output gearshaft 8 Drip some more 90 onto the radial needle roller bearings Copyright by Ulrico Becker 21 274 edition OVERDRIVE SERIES MANUAL qe vehicles Pre assembly of housing laygear main shaft and Place the needle roller bearing and the races RTC7184 fig 2 into the recess in the output gear shaft Drip some oil onto the inner diameter of the synchromesh cone and position it onto the output gear shaft Place the roller bearing 7173 fig 3 on top of the housing and carefully tap it home This can be done with a hammer and a suitable drift tapping always on opposite sides and after a few taps changing between the positions 12 and 6 and and 9 o clock Lubricate the bearing seat before presenting the bearing Do the same then with the oil seal part of RTC7173 fig taking care not to deform the seal during the tapping home Copyright by Ulrico Becker 22 274 edition 2 7 v OER Pre assembly of housing laygear main shaft and output gear shaft before final assembly Lubricate the bearing and grease the seal Put the housing into a vertical position and insert the laygear Lubricate
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