SAFARI

GEAR BOX G-76

SUB ASSEMBLY OF ENGAGING GEARS

Refer fig. 54, 55 & 56

Identify all the gears and needle bearing cages. The

gears are to be assembled in pairs of 1st/2nd, 3rd/

4th and Reverse/5th

Keep gear such that dog teeth are facing upwards.

Fit proper synchro cone. Fit proper engaging gear

over synchro cone, Fit other pair of gears.

Note :

While assembling 1st/2nd engaging gear the

longer shank to be on 2nd gear side. In the same

way for Reverse/5th engaging gear, the longer shank

to be assembled towards reverse gear.

Locate 3 Nos. carriers in slot of engaging gear such

that chamfer over carrier is facing outwards. Place

springs & balls at seat of carrier with help of grease.

Assemble proper shifter sleeve over engaging gear,

pressing all the balls simultaneously.

Note :

While assembling 3rd/4th gear, the shifter

sleeve (18) without groove to be fitted with broader

side towards 3rd gear.

While assembling 1st/2nd gear,

single groove side

of shifter sleeve (33) is to be assembled towards

2nd gear.

In Reverse/5th gear assembly,

fit double groove

side of shifter sleeve (38) towards reverse gear.

Fig. 56

Fig. 55

Fig. 54

Gear 3rd/4th assy.

Gear 1st/2nd assy.

Gear Rev. / 5th assy.