SAFARI

GEAR BOX G-76

DIS-ASSEMBLY OF GEAR CASE COVER-FRONT

Remove oil seal (3) with suitable punch.

Press out dowel pins (12), if required.

DISASSEMBLY OF GEAR CASE COVER - REAR

Refer fig. 46

Remove main shaft oil seal (43) from assy. gear case

cover rear (68) with suitable drift.

Unscrew and remove assy. threaded plug (50).

Remove oil seal speedo shaft (51).

Pull out plug speedo drive (47). Press out shaft

speedo drive (49) with suitable punch. Remove

speedo drive gear (48).

INSPECTION

Inspect inside of synchro cone for wear

Inspect the synchro cone teeth and matching teeth

on gear for wear (rounded off).

Fig. 47

Inspect the gear hub thrust surface for wear.

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

4th & 5th mainshaft gear; countershaft gears.

Inspect the teeth on all gears for uneven wear,

scoring, galling, 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.

Fig. 48

Check for synchro cone gaps. It should be

1 + 0.3 mm.

Fig. 48

Fig. 47

Fig. 46

Wear

Pressure

Check

gap with

feeler

gauge

Sectional View

48 49 50