SAFARI

GEAR BOX G-76

15. DIS-ASSEMBLY OF GEAR CASE COVER-

FRONT

Remove oil seal with suitable punch.

Press out dowel pins, if required.

DISASSEMBLYOF GEAR CASE COVER – REAR

Remove main shaft oil seal from assy. gear case cover

rear with suitable drift.

Unscrew and remove assy. threaded plug. Remove oil

seal speedo shaft.

Pull out plug speedo drive. Press out shaft speedo

drive with suitable punch. Remove speedo drive gear.

Ref Fig. 62

Fig. 62

16. INSPECTION

Inspect inside of synchro cone for wear.

Inspect the synchro cone teeth and matching teeth

on gear for wear (rounded off). Ref fig. 63

Inspect the gear hub thrust surface for wear.

Inspect the cone surface for wear on 1st, 2nd, 3rd, 4th

& 5th main shaft gear; countershaft gears.

Inspect the teeth on all gears for uneven wear, scoring,

galling, and cracks.

Place the synchro cone on matching gear cone and

rotate until it stops (approx. 10 to 20 degrees) then

measure the clearance between ring and gear. Ref

Fig. 64

Check for synchro cone gaps. It should be 1 + 0.3 mm.

Distance from rear cover outer wall to 3rd gear rear

side on counter shaft: 198 + 0.1 mm.

Distance from rear cover half outer wall to front end of

2nd gear on main shaft 197 + 0.1 mm.

Use sealing compound Maxi fixes s-758 Dunlop or

Duraplex 120 for sealing plugs.

Synchro Sleeve and Hub Inspection

Inspect the gear teeth on all synchro hubs and sleeves

for rounded off corners, indicating wear.

Install each hub in its mating sleeve and check for

freemovement.

Note: If replacement is required, always replace the

synchro sleeve and hub as a unit.

Fig. 63

Fig. 64